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

394

bald eagle watching over three eggs

MAY

2011

 


CONTENTS

AIRPLANES

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

DIAMOND.................................................................................................................................. 4

PIPER........................................................................................................................................... 5

HELICOPTERS

EUROCOPTER.......................................................................................................................... 11

POWERPLANTS

PRATT & WHITNEY................................................................................................................ 14

ACCESSORIES

MT PROPELLER....................................................................................................................... 16

SLICK MAGNETO................................................................................................................... 16

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:  177RG; Failed Nose Landing Gear; ATA 3230

This submitter says, "The nose landing gear failed to extend when the gear was lowered for landing—a nose gear 'up' landing (followed).  Examination revealed the up lock bell crank forward arm (that activates and disengages the up lock roller from the up lock hook) was found bent—and 90 per cent cracked (through).  It would not allow the up lock to disengage.  (The engine/nose gear mount was also found warped out of alignment—this was removed and repaired by a repair station.  The probable cause:  severe side loading during landing at an unknown time.)

"A new part was installed and a gear rigging check made per Cessna Manual, and no other problems were noted."  (Nose up lock P/N:  204303112.)


 

CLOSEUP VIEW OF BROKEN BELL CRANK.

 

Part Total Time:  3,216 hours

 

Cessna:  P206E; Cracked Bulkhead; ATA 5312

A technician states, "During inspection per AD72-07-09 (10/17/1974) and Service Letter SE72-3, the aft bulkhead (P/N 1212858-2) was found cracked in both rudder cable cut outs.  Upon removal of the aft bulkhead, the left and right stabilizer attach brackets (P/N's 0712629-3 and -4) were also found cracked." 


CLOSEUP VIEW OF CRACKED BULKHEAD.

CLOSEUP VIEW OF CRACKED ATTACH FLANGE (L/H).


 

CLOSEUP VIEW OF CRACKED ATTACH FLANGE (R/H).

(The SDRS database reflects the -2 bulkhead part number at least five times.)

Part Total Time:  5,287.0 hours

 

Diamond:  DA40; Cracked Heat Exchanger Exhaust; ATA 2140

An unidentified writer says, "In accordance with Power Flow System's 'Continued Airworthiness Instructions' (dated 7/22/2008), paragraph 7.0 states, 'The exhaust system must be thoroughly inspected, especially within the heat exchanger section...'.  During a 100 hour inspection of this airplane a crack was found in the chain weld at the exhaust exit ball and the heat exchanger cover.  The cracks start at the finish point of the weld and continue through the center of the weld—to the start point of the weld segment.  Paragraph 5.4.1 'Maximizing Service Life' states, 'Dynamically balance your propeller to below 0.2 ips (inch per second)  every two years or 1000 hours (whichever occurs first).'  This aircraft was manufactured in 2009 and has 398.6 hours since new."  (Heat exchanger P/N: 41303; Exhaust assembly component number:  PFS15102.)


 

CLOSEUP VIEW OF CRACKED EXHAUST DUCT.

 

Part Total Time:  398.6 hours

 

Piper:  PA24-260; Cracked Rudder Hinge Castings; ATA 5540

(The following combines two similar reports—the second on a Piper 24-400.  The wording is identical on both reports.)

A mechanic writes, "The top rudder hinge casting is cracked at the roller bearing location."  (Displayed drawing and P/N for the 24-260: 20707-02.  P/N for the 24-400:  20707-06; drawing is similar.  A parts list might have resolved the mystery why the photo shows P/N 20707-8!  However, the location and problem is quite clear; thanks—Ed.)


 

CLOSEUP VIEW OF CRACKED RUDDER HINGE CASTINGS (2 EACH).


CATALOGUE PARTS DARWING OF THE RUDDER ASSEMBLY.

Part(s) Total Time:  (unknown)

 


Piper:  PA28-140; Wing Spar Corrosion; ATA 5711

"Corrosion (has been found) on the right wing spar aft side," says an unidentified technician, "at wing station 59-61 (and) the fuel tank flexible access."  (Wing spar P/N:  6207001.)

 

CLOSEUP OF SPAR CORROSION.


 

CLOSEUP OF SPAR CORROSION & LABELED IDENTIFIERS.

VIEW OF SPAR AFTER REMOVING CORROSION.


 

CLOSEUP OF SPAR AFTER REMOVING CORROSION.

 

(As typical, the above photos have been artistically "squashed" by this editor.  Thank-you for the scary pictures!)

Part Total Time:  4,114.0 hours

 


HELICOPTERS

Eurocopter:  AS350-B2; Vertical Stabilizer Rivet Failure; ATA 5302

This submitter states, "Visual inspection of the vertical fin revealed leading edge movement.  Removal of the attachment bolts (exposed) sheared rivets."  (Vertical fin P/N:  350A14201101.  Total cycles: 15,403.)

 

CLOSEUP OF L.E. VERTICAL STABILIZER SHOWING SHEARED RIVETS.


 

CLOSEUP VIEW OF L.E. VERTICAL STABILIZER SHOWING ATTACH STRUCTURE.

 

Part Total Time:  6,178.0 hours

 

Eurocopter:  EC130-B4; Cracked Tail Boom Structure; ATA 5302

(About this defect our intrepid mechanic writes, "Cracked tail boom."  He can be forgiven the lack of specific placement and detailed description because of the most excellent photo—folks who work this bird will know exactly where to look.  Speculation as to cause of this crack would have been interesting.  Listed total cycles are: 6,682—Ed.)


 

CLOSEUP OF CRACKED TAIL BOOM STRUCTURE.

 

Part Total Time:  2,613.1 hours

 


POWERPLANTS

Pratt & Whitney:  PT6A-114; Defective Small Exit Duct; ATA 7240

A Chief Inspector for a repair station describes the following defect.  "During a hot section inspection (HSI), the small exit duct (SED) required replacement.  A replacement, overhauled SED with the same part number as the original SED was used in the build-up of the I.E. duct assembly.  The I.E. duct assembly was installed in the engine, but when the technicians attempted to install the burner can it would not fit around the SED.  After several unsuccessful attempts to install the burner can, the technicians removed the I.E. duct assembly and attempted to fit the burner can around the SED (while) sitting on a table.  They were unsuccessful in the attempt.  The assembly was then taken back to the vendor who had performed the HSI, and they found the inner wall of the SED had a gap between it and the outer wall as compared to a new unit.  The vendor then changed out the SED for a new unit in their shop, which allowed the burner can to easily slip around the I.E. duct assembly.  This new unit had no gap between its walls."

 

VIEW OF SED DUCT SITTING ON TABLE.


 

TOP VIEW OF GOOD AND BAD SED DUCTS---ONE SHOWING GAP.

(Small Exit Duct P/N:  3029248.)

Part Total Time (since overhaul):  0.0 hours

 


ACCESSORIES

MT Propeller: MTV-12-B; Cracked Mount Nuts; ATA 6110

(This report references a Diamond DA40 aircraft sporting a Continental IO360 engine..)

A repair station technician states, "When removing this propeller for reseal, (I) found two mounting nuts cracked.  The propeller has 93.5 hours since installation.  This propeller previously had the blades replaced due to a propeller strike."

Part Total Time:  353.3 hours

 

Slick Magneto:  6314; Overheat Failure,  ATA 7414

(The following report references a Cirrus SR20 towed by a Continental IO360 engine.)

This writer says, "During a 500 hour inspection compliance of the Champion Slick 6314 magnetos, the left hand magneto showed signs of extreme internal heat.  Slick SB (service bulletin) SB#-08A address the problem (as) caused by 'soft' carbon brushes packaged from September 1, 2004 through August 14, 2008.  Champion Magneto Maintenance and Overhaul Manual (number L-1363E, chapter 3) lists a 500 hour inspection procedure and various other periodic inspection procedures.  The total time of this magneto was documented as 1,672.8 hours.  The magneto case screw had the factory applied torque seal in place.  The breaker point assembly had plastic material melted around it.  Further disassembly revealed the source of the melted plastic as material from the distributer block and gear assembly—the carbon brush was severely worn as described and illustrated in SB3-08A, page 2.  I have included photographs in this report. 

"I am surprised an Airworthiness Directive has not been issued for this component.  I have seen two other magnetos in this condition, and many more with excessive wearing of the carbon brush in magnetos with far less time.  There is no regulatory limitation in the L-1363E manual for the number of hours allowed to accumulate before any required inspection on this component."


 

VIEW OF OPENED MAGNETO.

CLOSEUP PHOTO OF BURNED STRUCTURE (VIEW 1).


 

CLOSEUP PHOTO OF BURNED STRUCTURE (VIEW 2).


 

CLOSEUP PHOTO OF BURNED CONTACT POINTS.

 

Part Total Time:  1,672.8 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

CA101015008

 

 

 

WHEEL HALF

CRACKED

10/13/2010

 

 

 

 

MLG  

MAIN WHEEL CAME INTO SHOP FOR LOW TIRE PRESSURE, SNAG 75PSI, WO256316, NR003 AND PUT ONTO SHOP WO 256978 WHERE THE TIRE WAS REMOVED AND THE WHEEL UNDERGOES STANDARD EDDY CURRENT CHECK WHERE IT WAS FOUND TO BE CRACKED APPROX 5" IN LENGTH ALONG THE BEAD FLANGE. MX IREEGULARITY FILED. WHEEL HAD 290 HRS/308 CYCLES SINCE LAST TIRE CHANGE (EDDY CURRENT) AND 334 HRS/401 CYCLES SINCE INSP BEFORE THAT WHERE A VERY SLIGHT EDDY CURRENT INDICATION WAS NOTED IN THE SAME AREA AS WHERE THE CRACK HAS SINCE FORMED. THIS IS THE SAME AREA AS A PREVIOUS WHEEL FLANGE HAD CRACKED ON A PREVIOUS SDR 20100611005 WHEEL HAS SINCE BEEN SHIPPED TO THE MFG FOR METALURGICAL ANAYLSIS. CRACK WAS FOUND USING ANDEC NDT WHEEL MACHINE.

CA100928009

 

 

 

BULKHEAD

CRACKED

9/28/2010

 

 

 

34A01158238

FLOAT

CRACKED AT BOTTOM IN THE V SHAPE. ALL FLOATS ARE CRACKED AT THIS STA (SN 34121, 34122, 34123 AND 34124).

CA100930005

 

 

 

BEARING

MISMANUFACTURED

9/30/2010

 

 

 

SB2559101

M/R GEARBOX

BEARING, PN SB2559-101, SN 0799, WO 5402643ACMR F1002402, PO 2120265, NEW BEARING ROLLERS AND ROLLER CAGE DO NOT ROTATE WHEN INSTALLED ON BEARING SUPPORT. FINAL INSP PROCEDURE BY OEM TO BE REVIEWED AND INCREASE INSP CRITERIA. SQID SENT TO QA FOR INVESTIGATION AND TCCA SDR RAISED.

2011FA0000172

 

 

 

TRANSFORMER

FAILED

3/1/2011

 

 

 

1000661

STATIC INVERTER

THE STATIC INVERTER WAS RECEIVED FOR REPAIR AND ISSUED ON OUT WO R11-01116. THE INVERTER`S COVER HAD ANOTHER REPAIR FACILITY`S ANTI-TAMPER STICKER ATTACHED AND INTACT. DURING DURING DISASSEMBLY OF THE INVERTER, OUR TECH NOTED A LARGE AMOUNT OF WHAT APPEARED TO BE SILICONE SEALANT BENEATH THE OUTPUT TRANSFORMER. THE TRANSFORMER IS SECURED TO ITS BASE BY 2 THIN METAL BANDS WHICH WRAP AROUND THE TRANSFORMER AND THE BASE IS BOLTED TO THE CHASSIS. OUR TECH STATED THAT THE BAND IS SOMETIMES FOUND TO BE BROKENAS WAS THE CASE WITH THIS TRANSFORMER. A BROKEN BAND ALLOWS THE TRANSFORMER COIL TO "FLOP AROUND" IN THE INVERTER, ONLY BEING RETAINED BY ITS WIRES. REPLACEMENT OF THE TRANSFORMER IS REQUIRED IF 1 OR BOTH BANDS ARE BROKEN. IT APPEARS THAT THE SILICONE SEALANT WAS APPLIED TO SECURE THE TRANSFORMER FROM MOVEMENT.

2011FA0000199

 

 

MARVELSCHEBX

SLEEVE

LOOSE

3/7/2011

 

 

 

86151

MIXTURE

DURING INSPECTION, THE MIXTURE CONTROL SLEEVE WAS FOUND LOOSE IN THE THROTTLE BODY. THE THROTTLE BODY WAS SENT FOR SB 18 COMPLIANCE. MSA CONFIRMS THE FINDINGS THAT WERE REPORTED. THE SLEEVE HAD REPORTEDLY ROTATED AND FUEL STARVATION HAD OCCURRED. THIS RESULTED IN POWER LOSS. THIS REPAIR STATION REITERATES THE IMPORTANCE OF HAVEING CARBURETORS AFFECTED BY SB 18 INSPECTED BEFORE FURTHER FLIGHT.

2011FA0000125

 

 

 

LIFE RAFT

DAMAGED

2/23/2011

 

 

 

1015FAUL1901204

 

DURING ROUTINE INSPECTION OF THIS LIFE RAFT, TWO SEPARATE ISSUES WERE IDENTIFIED AS FOLLOWS: DURING PRELIMINARY INSPECTION, IT WAS OBSERVED THAT THE FIRING HEAD CABLE HAD BEEN ROUTED UNDER THE VALISE LACING AS TO POSSIBLY PREVENT NORMAL INFLATION OF THE LIFE RAFT. THIS STATION CONTACTED FSDO-11 WHO ADVISED SUBMISSION OF THIS FORM AND REQUESTED PHOTOS OF THE SUBJECT LIFE RAFT. AFTER REMOVING THE LIFE RAFT FROM THE VALISE, IT WAS OBSERVED THAT THE BURST STRIP HAS NOT BEEN PRE-CUT PRIOR TO VACUUM PACKING. BURST STRIP CUTTING IS REQUIRED TO INSURE PROPER INFLATION OF THE RAFT. FSDO 11 WAS NOTIFIED AND PHOTOS OF THIS ITEM HAVE BEEN SENT TO FSDO-11.

2011FA0000177

 

 

 

LIFE VEST

MISOVERHAULED

3/15/2011

 

 

 

P0723E105P

CABIN

HAD 2 LIFE VESTS RECERTIFIED. WHEN RECEIVED THEM BACK, THE SEALED BAGS HAD A SMALL SEPARATION OF THE SEAL. UPON FURTHER EXAMINATION BY FEELING THE PACKAGED VEST, DID NOT DETECT CO2 CARTRIDGES. OPENED THE POUCHES AND FOUND THAT THE CO2 CARTRIDGES WERE IN FACT MISSING ON BOTH VESTS. THIS IS A VERY SERIOUS ISSUE AS THE VESTS ARE A SEALED PACKAGE AND HAVE TO TRUST THAT THEY ARE COMPLETE AND WILL BE READY WHEN CALLED UPON. THERE IS NO TESTING OF THESE OTHER THAN SENDING THEM IN FOR RECERTIFICATION. IF THE BAG DID NOT HAVE A SEPARATION OF THE SEAL, THEY COULD HAVE BEEN INSTALLED IN THE ACFT IN THIS CONDITION. THE VESTS WERE SENT FOR RECTIFICATION.

2011FA0000232

 

CONT

 

GEAR

CRACKED

2/17/2011

 

IO240B

 

655422

CAMSHAFT

DURING MAG PARTICLE INSP, DISCOVERED MULTIPLE (3) CRACKS RUNNING FROM ROOTS OF OUTSIDE GEAR TO ROOTS OF INSIDE GEAR CONTINUING TO FADEC TIMING HOLES IN GEAR DISC. OF 3 GEARS OF THIS PN, INSPECTED WITHIN LAST 2 WEEKS, 2 HAVE EXHIBITED IDENTICAL CRACKS. THIS PN WITH FADEC TIMING HOLES HAS SUPERSEDED THE PREVIOUS PART WITHOUT HOLES FOR BOTH "DIGITAL" AND "ANALOG" ENGINES IAW MFG. CONTACTED MFG VIA PHONE 17 FEB 2011.

2011FA0000233

 

CONT

 

GEAR

CRACKED

2/17/2011

 

IO240B

 

655422

CAMSHAFT

DURING MAG PARTICLE INSP, DISCOVERED CRACK RUNNING FROM ROOT OF OUTSIDE GEAR TO ROOT OF INSIDE GEAR CONTINUING TO FADEC TIMING HOLE IN GEAR DISC. OF 3 GEAR OF THIS PN INSPECTED WITHIN THE LAST 2 WEEKS, 2 HAVE EXHIBITED IDENTICAL CRACKS. THIS PN WITH FADEC TIMING HOLES HAS SUPERSEDED THE PREVIOUS PART WITHOUT HLES FOR BOTH "DIGITAL" AND "ANALOG" ENGINES IAW MFG. CONTACTED MFG VIA PHONE 17 FEB 2011.

2011FA0000198

 

CONT

CONT

COUNTERWEIGHT

WRONG PART

2/28/2011

 

TSIO550E

 

639196

CRANKSHAFT

FACTORY NEW ENGINE AT DISASSEMBLY HAD 3 EA 639195 COUNTERWEIGHT AND 1 EA 639196 COUNTERWEIGHT INSTALLED. SB00-3 STATES THAT 2 EA 639195 AND 2 EA 639196 COUNTERWEIGHTS ARE REQUIRED.

2011FA0000110

 

LYC   

 

IDLER GEAR

MAKING METAL

2/16/2011

 

LTS101700D2

LTS101700D2

408135018

AGB  

ENGINE WAS RECEIVED FOR MX. CUSTOMER CLAIMED ENGINE WAS MAKING METAL. ENGINE WAS DISASSEMBLED TO INVESTIGATE THE SOURCE OF THE PROBLEM. REMOVED AGB MODULE'S COVER TO INSPECT BEARINGS AND GEARS. FOUND ONE BOLT HEAD SHEARED OFF OF THE TORQUE IDLER GEAR. THE TORQUE IDLER GEAR IS MADE OF 2 GEARS THAT ARE PRESSED FITTED AND THEN SECURED BY 8 THROUGH BOLTS AND NUTS. MOST OF THE (8) NUTS WERE LOOSE AND THERE WERE CHIPPED AREAS ON SOME OF THEM. OEM ENGINEERING HAS BEEN NOTIFIED AND ARE INVESTIGATING THIS MATTER.

2011FA0000175

 

LYC   

 

CRANKSHAFT

CORRODED

3/11/2011

 

O235L2C

 

LW12696

ENGINE

ENGINE WAS O/H 03/12/05, AT THAT TIME SB530B WAS C/W. ENGINE IS NOW HERE FOR O/H AND UPON INSP OF CRANKSHAFT BORE (AFTER CLEANING AND REMOVAL OF OLD PID COATING) SHOWS SUBSTANTUAL PITTING IN BORE. CRANKSHAFT REJECTED, RED TAGED. I HAVE SEEN THIS PROBLEM MANY TIMES BEFORE AND HAVE THESE REJECTED CRANKSHAFTS IN MY POSSESSION. I THINK THIS PROTECTIVE COATING APPLIED TO THE CRANKSHAFTS IS INEFECTIVE IN PREVENTING THIS CORROSION PITTING. REF LYC MANDATORY SB NR 530B.

CA100903003

 

PWA   

 

ENGINE

INOPERATIVE

8/20/2010

 

PT6*

 

 

 

POWER ROLLBACK, ENG POWER SLOWLY DECREASED TO IDLE POWER DURING CRUISE. ENG DID NOT RESPOND TO PLA INCREASE TO MAXIMUM. THE PILOT SELECTED THE BLEED AIR SYS SWITCH TO "OFF". ENG POWER RECOVERED SOME POWER BUT WAS STILL LOW. PILOT THEN SELECTED THE BLEED AIR SYS SWITCH TO "ENVIRO OFF" WHICH TOTALLY CLOSES BLEED AIR OFF. ENG POWER FULLY RECOVERED, HOWEVER, PLA RESPONSE WAS SLOW. PILOT RETURNED TO THE ACFT THE NEXT DAY AND ATTEMPTED AN ENGINE START. THE ENG HUNG AT 35 PERCENT NG AND 650 CELCIUS T5. THERE WAS NO RESPONSE TO CLA OR PLA INCREASE. HE SHUTDOWN THE ENG AND CONTACTED HBC.

CA100928005

 

PWA   

 

POWERPLANT

FAILED

9/24/2010

 

PT6A68

 

 

 

ACCIDENT IT WAS REPORTED THAT DURING A PILOT TRAINING FLIGHT ACFT CRASHED AFTER EXPERIENCING ENGINE TROUBLE. BOTH CREW MEMBERS WERE ABLE TO SUCCESSFULLY EJECT AND ARE UNINJURED. MFG ASSISTANCE HAS BEEN OFFERED TO THE USAF SAFETY BOARD. MFG SERVICE INVESTIGATION REMAIN ON STANDBY SHOULD ON-SITE ASSISTANCE BE REQUIRED.

CA100924006

 

PWA   

 

CYLINDER

CRACKED

9/22/2010

 

R183092

 

 

ENGINE

ENGINE HAD BOUNCING MANIFOLD PRESSURE AT POWER REDUCTION. UPON INSP, FOUND THAT THE NR1 CYLINDER ASSY HAD CRACKED AT THE EXHAUST EAR CAUSING VALVE TO NOT OPEN AND CLOSE PROPERLY.

AC2R9JP03062011

AGUSTA

 

 

LINK

CRACKED

3/3/2011

AW139

 

 

3G6220A00531

MAIN ROTOR

FOUND MAIN ROTOR TENSION LINK CRACKED DURING VISUAL INSPECTION. REPLACED TENSION LINK.

2011FA0000222

AIRBUS

PWA   

 

JACKSCREW

OUT OF POSITION

2/18/2011

A310324

PW4152

 

FE140

STABILIZER

DURING O/H, MX PERFORMED ON THE SCREW JACK ASSY, FE140 SN 125, IDENTIFICATION OF THE WRONG POSITIONING OF THE RATCHET WHEEL (ITEM 3-620 OF CMM 27-44-13), ASSEMBLED ON THE OPPOSITE POSITION COMPARED TO THE SPEC MENTIONED ON THE CMM 27-44-13. LETTER LT-S9-11-106 + TECH REPORT (RF-DSC-438/11 V00) THIS MISASSEMBLY LEADS TO AN INOPERATIVE NO-BACK OF THE SCREW JACK ASSY ON COMPRESSIVE LOAD DIRECTION ONLY. THE PROBABLE CAUSE COULD BE A MISASSEMBLY OF THE RATCHET WHEEL DURING THE LAST REPAIR OF THE SCREW JACK ASSY IN A REPAIR STATION THAT REMAINS UNDETERMINED. OPEN

EE4Y20110129

AIRBUS

 

 

FLOOR SUPPORT

CORRODED

2/25/2011

A319132

 

 

D5347217220500

ZONE 200

UPPER FUSELAGE PAX CABIN AFT ENTRANCE AREA FROM STA 2800 TO STA 2872 BETWEEN -Y116 AND -Y129 FLOOR SUPPORT BEAM WITH CORROSION. DAMAGED PART WAS REPLACED IN ACCORDANCE WITH SRM 51-72-11 PARAGRAPH 4 AND 6.

EE4Y20110128

AIRBUS

 

 

FLOOR SUPPORT

CORRODED

2/25/2011

A319132

 

 

D5347217220400

ZONE 200

UPPER FUSELAGE PAX CABIN AFT ENTRANCE AREA FROM STA 2800 TO STA 2872 BETWEEN +Y116 TO +Y129 FLOOR SÙPPORT BEAM WITH CORROSION. CORRECTIVE ACTION: DAMAGED PART WAS REPLACED IN ACCORDANCE WITH A319 SRM 51-72-11 PARAGRAPH 4 AND 6.

CA100930009

AIRTRC

PWA   

 

WASHER

MISINSTALLED

9/30/2010

AT802A

PT6A67

9388013

 

ENGINE MOUNT

WASHERS ARE INSTALLED AT THE FACTORY UNDER THE HEADS OF THE 4 BOLTS THAT MOUNT THE BARRY MOUNTS, PN 93880-13 TO THE ENGINE. THROUGH COMMUNICATIONS WITH THE MOUNT AND ACFT MFG, DISCOVERED THAT THE WASHERS SHOULD NOT BE INSTALLED. THE WASHERS CAUSE THE BOLTS TO SIT HIGHER AND RUB ON THE MOUNTS CAUSING PREMATURE WEAR AND CHANGING OUT OF MOUNT PREMATURELY.

CA100923009

AIRTRC

PWA   

AIRTRC

SCREW

WRONG PART

9/9/2010

AT802A

PT6A67A

1106825

 

COCKPIT SHOULDER

WHILE CARRYING OUT THE INSTALLATION OF THE AIR BAG SYS INTO ACFT, THE 2 LAP BELT INFLATOR TUBES BECAME DAMAGED DUE TO CHAFING/CATCHING ON SCREWS USED IN THE INSTALLATION. THE DAMAGE WAS NOT BEYOND LIMITS AS LISTED IN THE AIR BAG SICA. THE PROBLEM STEMS FROM THE SCREWS BEING TOO LONG FOR THE INSTALLATION. ALL AIR BAG INSTALLATIONS ON ACFT MAY BE AFFECTED BY THIS.

CA100930002

AIRTRC

PWA   

 

CONTROL CABLE

DAMAGED

9/27/2010

AT802A

PT6A67A

 

WIPAIRE

FLOAT

WATER RUDDER RETRACT CABLES BECOME SPIKED WITHIN 100 HRS OF NEW INSTALL, WHERE CABLE RESTS ON NYLON PULLEY AT FLOAT AFT BULKHEAD. CABLE PIN, CABLE-RUDDER RETRACT (2) 10A08000-166.

CA100930003

AIRTRC

PWA   

 

ROLL PIN

MISINSTALLED

9/27/2010

AT802A

PT6A67A

 

98296A999

AILERON ELEVATOR

SERVERAL OF THE LARGE DIAMETER HOLLOW FLIGHT CONTROL PUSH TUBES HAVE THEIR ROD ENDS HELD ON WITH ROLL PINS. THESE ROLL PINS SHOULD BE LOCKWIRED AROUND THE TUBE TO PREVENT THE ROLL PIN FROM FALLING OUT IF IT GETS LOOSE.

CWQD.2011.05

AMD   

 

 

RESISTOR

OVERTEMP

4/12/2011

FALCON2000

 

 

FGFB641830A1

WINDSHIELD HEAT

RT HALF OF CENTER WINDSHIELD NOT HEATING. TROUBLESHOT TO RT WINDSHIELD RESISTOR BOX BROKEN OFF AT CONNECTION POINT AND GROUND WIRE AT TERMINAL NR 3 OVERHEATED.

2011FA0000164

BBAVIA

 

 

SPINNER

LOOSE

3/10/2011

7EC   

 

 

 

PROPELLER

SKULL CAP SPINNER BECAME LOOSE AND DEPARTED THE ACFT. EVIDENCE OF THE SPINNER ABRADING THE .041 SS SAFETY WIRE AT THE HEAD OF THE RETAINING BOLTS WAS EVIDENT. TORQUE ON THE WOODEN PROPELLER BOLTS HAD NOT BEEN CHECKED FOR PROPER TORQUE SINCE NEW. SINCE THE SAFETY WIRE WAS COMPROMISED 3 BOLTS LOOSENED OUTWARD WITH A SPACE UP TO 1.5 INCHES BETWEEN THE OUTER SURFACE OF THE CRUSH PLATE AND THE HEAD OF THE BOLT. THE RESULTANT VIBRATION DAMAGED THE WOODEN PROPELLER ATTACHMENT HOLES BEYOND SERVICEABILITY. THE ADAPTER PLATE INSERTS WERE DAMAGED AND REQUIRED REPLACEMENT OF THE ADAPTER PLATE AND THE INSERTS. NEW PROPELLER AND ADAPTER PLATE WERE INSTALLED, PROPELLER ATTACHMENT BOLTS TORQUED TO PROPELLER MFG SPEC FOR A WOOD PROPELLER AND SAFETY WIRED WITH .041 SS SAFETY WIRE. UPON CONSULTATION WITH THE ACFT MFG, THE SKULL CAP ASSEMBLY WAS NOT REINSTALLED. OWNER WAS INSTRUCTED TO COMPLY WITH THE MFGS GUIDANCE ON RETORQUING THE PROPELLER BOLTS AT THE SPECIFIED INTERVALS.

VIBR20110315

BBAVIA

 

 

ELEVATOR

MISOVERHAULED

3/15/2011

7ECA

 

 

653400029

LEFT  

REMOVED LT ELEVATOR, PN 6534000-29, SN 0480 AND SENT TO MFG FOR REPAIR. ATTEMPTED TO INSTALL ELEVATOR AFTER REPAIR BY MFG. ELEVATOR HINGE POINT BOLT HOLES OUT OF ALIGNMENT, COULD NOT INSTALL ELEVATOR. ELEVATOR SENT BACK TO MFG FOR REPAIR/REWORK.

CA100816006

BBAVIA

LYC   

 

BRUSHES

BROKEN

8/10/2010

8GCBC

O360C2E

4370

AM3215

MAGNETO

FAA-PMA PART AM-3215 CARBON BRUSH AND SPRING WAS FOUND BROKEN OFF FLUSH WITH THE SPRING AND FELL INTO THE MAGNETO. CONTACT WAS MAINTAINED BY THE REMAINING PART OF THE BROKEN BRUSH. DURING THE PREINSPECTION RUN UP, THERE WERE NO INDICATIONS OF A PROBLEM. THE BROKEN OFF PARTS OF THE CARBON BRUSH WAS LOCATED DOWN BY THE COIL AND WAS DISLOGED BY TILTING THE MAGNETO UPSIDE DOWN AND SHAKING THE MAGNETO.

2011FA0000142

BEECH

PWA   

 

O-RING

PINCHED

2/22/2011

400BEECH

JT15D5

 

 

LT OIL FILTER

CREW EXPERIENCED LT ENGINE OIL PRESSURE FLUCTUATING. UPON COMPLETING EMERGENCY CHECK LIST OIL PRESSURE DROPPED BELOW 20PSI AND ENGINE WAS SHUT DOWN. SUBSEQUENT INSPECTION REVEALED A PINCHED O-RING IN THE MAIN ENGINE OIL FILTER HOUSING. O-RING WAS REPLACED AND ENGINE MAINTENANCE MANUAL PROCEDURES WERE ACCOMPLISHED,ENGINE OIL SERVICED AND ENGINE PERFORMANCE RUN ACCOMPLISHED.

H5GR20110218001

BEECH

 

 

SPAR

CRACKED

2/4/2011

58   

 

 

00243001811

ZONE 600

DURING THE ANNUAL INSP, A CRACK IN THE RT FWD SPAR, FWD WEB BEND RADIUS WAS NOTICED DURING A VISUAL INSP OF THE AREA. A DYE PENETRANT INSP WAS PERFORMED AND CRACK VERIFIED. INSP WAS PERFORMED FOLLOWING MM, PN: 55-590000-13G, REV G2, SECTION 53-00-00, PAGE 202, B(1) WING FORWARD SPAR CARRY-THROUGH STRUCTURE INSP WITHOUT REPAIR KIT. ACFT THEN FLOWN TO OUR FACILITY FOR VERIFICATION OF THE CRACK AND INSTALLATION OF KIT PN 58-4008-9. IT SHOULD BE NOTED THAT AD90-08-14: WING SPAR STRUCTURE, AS WELL AS, MSB2269, REV 1: FUSELAGE - WING FWD SPAR CARRY-THROUGH STRUCTURE INSP AND/OR REINFORCEMENT ARE NOT APPLICABLE TO THIS ACFT BY SN. THE CRACK WAS FOUND IN THE AREA AS REFERENCED IN BOTH THE AD AND MSB, BUT STOP APPLICABILITY FOR THIS ACFT. THE KIT, PN 58-4008-9 WAS INSTALLED ON BOTH THE RT AND THE LT FWD SPAR FWD WEB STRUCTURE IAW KIT INFORMATION - REINFORCEMENT INSTALLATION INSTRUCTIONS DWG NR 58-4009 AND KIT INFORMATION DWG NR 58-4008, REV C.

2011FA0000147

BEECH

CONT

 

PITCH ROD

GROOVED

3/3/2011

58   

IO550*

 

D3474

PROPELLER

DURING O/H EVALUATION, FOUND PITCH CHANGE ROD PN D3474 TO BE WORN UNDER MINIMUM DIMENSIONS. ROD WAS INSTALLED ON JAN 26, 2011 DURING A REPAIR, IT HAD 30.8 HOURS SINCE NEW.

2011FA0000162

BEECH

CONT

 

SWITCH

BURNED

3/9/2011

58   

IO550C

 

35380132105

TAXI LIGHT

PILOT REPORTED A BURNING SMELL IN THE CABIN. AN INSP REVEALED THE TAXI LIGHT CIRCUIT BREAKER SWITCH TO HAVE AN UNUSUAL FEEL. FOLLOWING REPLACEMENT OF THE SWITCH, THE FAILED SWITCH WAS DISASSEMBLED AND FOUND TO HAVE BURNED INTERNAL COMPONENTS. THIS SWITCH, PN 35-380132-105, IS THE IMPROVED MODEL THAT WAS REQUIRED BY AD 2008-13-07 WHICH WAS MODIFIED TO PREVENT THE BURNING SITUATION IN THE FAILURE MODE. THIS WAS ACCOMPLISHED BY INSTALLING 2 INSULATOR PADS AT THE ACTUATOR SPRING TO PREVENT CURRENT FROM FLOWING THROUGH THE SPRING WHEN THE WIRE BRAID FAILS. UNFORTUNATELY, WHEN THESE SWITCHES OVERHEAT, IT IS DIFFICULT TO IMPOSSIBLE TO DETERMINE IF THE INSULATORS HAD BEEN INSTALLED IMPROPERLY OR INSTALLED AT ALL. THIS IS THE SECOND POST AD SWITCH IN OUR FLEET THAT HAS FAILED AND OVERHEATED.

YHLR20119403

BEECH

 

 

DISPLAY

FALSE INDICATION

2/23/2011

76   

 

 

91000001001

COCKPIT

ATTITUDE DISPLAY SLOWLY ROLLS RT AND PITCHES DOWNWARD ON GROUND AND IN FLIGHT. REPLACED EFD-1000 PRO DISPLAY AS REQUIRED. PERFORMED SYS OPS CHECKS IAW EFD1000 INSTALLATION MANUAL 900-00003-001.

YHLR20109297

BEECH

 

 

CONNECTOR

CONTAMINATED

11/30/2010

76   

 

 

 

ACU  

NO VOR NR 2 DISPLAY ON PFD, ACU BREAKER POPS. ISOLATED TO ACU. FOUND EVIDENCE OF WATER ON CONNECTORS. REPLACED ACU AS REQUIRED. PERFORMED SYS OPS CHECKS IAW INSTALLATION MANUAL 900-00003-001.

YHLR20119363

BEECH

 

 

CONTROL UNIT

FAILED

1/27/2011

76   

 

 

91000004001

 

ACU BREAKER IS POPPED. ISOLATED TO ACU. POSSIBLE POWER SPIKE DAMAGED ACU. REPLACED ACU AS REQUIRED. PERFORMED SYSTEM OPERATIONAL CHECKS IN ACCORDANCE WITH ASPEN AVIONICS EFD1000 INSTALLATION MANUAL 900-00003-001.

2011FA0000220

BEECH

LYC   

 

BEARING

LEAKING

3/24/2011

76   

LO360A1G6

 

 

PROP BLADE

THE BUTT BEARING IS OVER THE MAX ALLOWED DIAMETER ALLOWING THE BEARINGS TO FLOAT FREE IN THE BLADE BORE. THE PROP WAS DISASSEMBLED FOR RESEAL DUE TO GREASE LEAKAGE. DURING INSP, THE BLADE WAS FOUND TO BE LEAKING OIL BETWEEN THE BLADE AND BUTT BEARING. THE BEARING WAS PULLED AND THERE WAS EPOXY FOUND IN 1 BLADE AND ZINC CHROMATE IN THE OTHER BLADE ATTEMPTING TO HOLD THE BEARINGS IN PLACE. THE BEARING BORE WAS MEASURED AND WAS FOUND TO BE BETWEEN .002 AND.004 OVERSIZE FROM MFG SPEC. THE BORE WAS EXAMINED AND WAS FOUND TO HAVE BEEN REWORKED PAST LIMITS DURING THE LAST O/H.

2011FA0000136

BEECH

GARRTT

 

FUEL NOZZLE

CRACKED

2/14/2011

B100

TPE3316252B

 

31024681

LT ENGINE

AFTER TAKING OFF, LEFT ENGINE STARTED LOOSING POWER IN FLIGHT. PILOT DECIDED TO RETURN TO DEPARTURE. ACFT LANDED SAFELY. ACFT WAS THEN PLACED FOR INSPECTION. FOUND THE LT ENGINE SECONDARY FUEL MANIFOLD CRACKED AND LEAKING FUEL. CORRECTED THIS BY CLEANING ALL RESIDUE FUEL FROM NACELLE AND ACFT. INSTALLED SERVICEABLE SECONDARY FUEL NOZZLE ASSY, (PN 3102468-1),. ACFT ENGINES WERE RUN FOR INSPECTION AND LEAK CHECKS. FOUND LT ENGINE TURBINE SEAL LEAKING AT EXHAUST PIPE. ENGINE WAS REMOVED, TURBINE SEAL REMOVED, INSTALLED NEW TURBINE SEAL (PN 896494-3) AND TURBINE SEAL ROTOR (PN 896549-2. ACFT ENGINE WERE RUN AND FOUND SATISFACTORY AT THIS TIME. ACFT RETURNED TO SERVICE.

2011FA0000111

BEECH

 

 

DISPLAY

MALFUNCTIONED

12/16/2010

B200C

 

 

70000167003

INSTRUMENT PANEL

ON THE EX600 MFD WHICH HAD JUST BEEN INSTALLED IN AUGUST OF 2010, THE PILOT REPORTED THE FOLLOWING MESSAGES WERE DISPLAYED: BROADCAST RECEIVER NOT COMMUNICATING, BROADCAST DATA NOT YET RECEIVED. THE MFD WOULD NOT DISPLAY THE WEATHER DATA FROM THE WSI-301. MX CONFIRMED THE SYS MALFUNCTION/ERROR. REPLACEMENT MFD UNIT WAS RECEIVED AND INSTALLED, CONFIGURED, AND OPS CHECKED SATISFACTORY.

2011FA0000112

BEECH

 

 

DISPLAY

MALFUNCTIONED

2/15/2011

B200C

 

 

70000167003

INSTRUMENT PANEL

THE PILOT REPORTED THE EX600 MFD DISPLAY REMAINED DIM AND NOT LEGIBLE FOR APPROX 10 TO 15 MINUTES DURING THE ACFT GROUND RUN-UP CHECKS PRIOR TO TAXI. WHEN THE DISPLAY ACHIEVED 'NORMAL' BRIGHTNESS AND WAS READABLE IN DAYLIGHT CONDITIONS, ALL THE ASSOCIATED FUNCTIONS PERFORMED IN A NORMAL MANNER. A WARRANTY EXCHANGE MFD IS BEING PROCURED. THIS IS THE SECOND EX600 MFD WITH A DISPLAY PROBLEM WE HAVE ENCOUNTERED IN THE PAST 6 MONTHS ON THIS ACFT. THE AVIONICS SHOP SUPPLYING THE WARRANTY REPLACEMENT MFD STATED THEY KNOW OF 4 OTHER UNITS THAT HAVE EXHIBITED SIMILAR PROBLEMS.

2011FA0000170

BEECH

LYC   

 

ATTACH FITTING

CORRODED

2/19/2011

C23   

O360*

 

 

AILERON

RT FWD AILERON FAILED DUE TO CORROSION AT ATTACH POINT TO AILERON CONTROL ARM PN 169-5240201. CORROSION WAS ON LAST 6 INCHES OF CABLE AND WAS SMOOTH TO TOUCH. FAILED AFTER TAKEOFF APPROX 50 FT IN THE AIR, PLANE LANDED SAFELY. WOULD RECOMMEND SMALL INSPECTION MIRROR AND BRIGHT LIGHT FOR ANNUAL/100 HR INSP ALONG WITH LUBRICATION WITH APPROVED MATERIALS AND CLOTH TEST. WOULD ALSON RECOMMEND REMOVAL FROM ACFT EVERY 24 MONTHS FOR MORE THOROUGH INSP.

2011F00044

BEECH

 

 

CHANNEL

CHAFED

2/18/2011

C90   

 

 

5044003121

ELEVATOR

ELEVATOR MOVEMENT TO CERTAIN DISTANCE CAUSES POPPING SOUND IN EMPENNAGE. INVESTIGATION RESULTED IN FINDING THE ELEVATOR TRIM MOTOR TURNBUCKLE UPPER BOLT & NUT RUBBING AGAIN THE ELEVATOR RIGGING CHANNEL, CAUSING CHAFING.

CA101022004

BEECH

PWA   

PWC   

DRIVE GEAR

DETACHED

10/22/2010

D18S

R985AN14B

 

 

MAGNETO

MAG DROP OF GREATER THAN 100 RPM NOTICED ON RUN-UP. WHEN RT MAGNETO WAS REMOVED FROM THE ENG, IT WAS FOUND THAT THE NUT RETAINING THE MAGNETO DRIVE GEAR HAD FALLEN OFF, LIKELY THE RESULT OF A BROKEN COTTER PIN, CAUSING MAGNETO SPLINE AND FRONT BRG TO WEAR, EVENTUALLY CAUSING A CHANGE IN MAGNETO TIMING, AS WELL AS A LARGE QUANTITY OF METAL PARTICLES IN THE MAGNETO, BOTH OF WHICH MAY HAVE LED TO THE LOSS OF RPM. AS THE NUT WAS CAPTURED INSIDE OF THE RUBBER VERNIER COUPLING, THE FAULT COULD NOT BE SPOTTED WITHOUT THE COMPLETE REMOVAL OF THE MAGNETO FROM THE ENGINE.

2011FA0000154

BEECH

 

 

CONTROL CABLE

BROKEN

2/27/2011

E18S

 

 

4141870971

ELEVATORS

AFTER TAKEOFF PILOT HEARD A "SNAP". ACFT PITCHED UP. PILOT REALIZED HE HAD LOST DOWN ELEVATOR CONTROL. PILOT REGAINED CONTROL BY USE OF TRIM CONTROL AND POWER REDUCTION. ACFT RETURNED FOR A SUCCESSFUL LANDING. NOTE: THE TOTAL TIME ON THE CABLE IS UNKNOWN.

2011FA0000169

BEECH

CONT

 

OIL FILTER

FAILED

3/1/2011

E35   

E2258

 

AA48109

ENGINE

AFTER START UP AND A SHORT TAXI, THE PILOT NOTICED THAT THE ENGINE RAN ROUGH. SHUTDOWN & NOTICED THAT OIL WAS LEAKING FROM THE RT SIDE COWLING. IT WAS FOUND THAT THE OIL FILTER CAN WAS SEPARATING FROM THE BASE. THIS OCCURRED AFTER 6 CYLINDERS WERE REPLACED. MX RUN UPS WERE SATISFACTORY WITH NO LEAKS NOTED. TIME ON FILTER WAS 2.9 TENTHS. REASON FILTER SEPARATED IS UNKNOWN. THE FILTER CAN IS NORMAL WITH NO SIGNS OF BULGING.

2011FA0000103

BEECH

CONT

 

CIRCUIT BREAKER

FAILED

2/12/2011

F33A

IO520BB

 

35380132103

TAXI LIGHT

PILOT REPORTED TAXI LIGHT INOP. ON TROUBLESHOOTING, TECH FOUND CIRCUIT BREAKER/SWITCH TO BE AT FAULT. AD 2008-13-17 HAD BEEN COMPLETED 1398 FLIGHT HOURS PRIOR AND ESTIMATED CYCLES 5592. NOTICED NEW CIRCUIT BREAKER MFG. NO PROBABLE CAUSE OR RECOMMENDATIONS AT THIS TIME.

2011FA0000139

BEECH

CONT

 

CIRCUIT BREAKER

FAILED

3/1/2011

F33A

IO520BB

 

35380132103

LANDING LIGHT

PILOT REPORTED LANDING LIGHT INOP.ON TROUBLESHOOTING TECHNICIAN FOUND THE CIRCUIT BREAKER/SWITCH TO BE AT FAULT. A.D.2008-13-17 HAD BEEN COMPLETED 1551 FLIGHT HOURS PRIOR AND ESTIMATED CYCLES 6204. NO PROBABLE CAUSE OR RECOMMENDATIONS AT THIS TIME.

2011FA0000176

BEECH

CONT

 

CIRCUIT BREAKER

FAILED

3/13/2011

F33A

IO520BB

 

35380132101

NAVAGATION LIGHT

PILOT REPORTED NAV LIGHTS INOP. ON TROUBLESHOOTING TECH FOUND CIRCUIT BREAKER/SWITCH TO BE AT FAULT. AD 2008-13-17 HAD BEEN COMPLETED 1776 FLIGHT HRS PRIOR AND ESTIMATED CYCLES 7104. NOTICED NEW CIRCUIT BREAKER MFG. NO PROBABLE CAUSE OR RECOMMENDATIONS AT THIS TIME.

2011FA0000109

BEECH

CONT

 

PUMP

LOW PRESSURE

2/16/2011

F33A

IO520BB

 

 

PNEUMATIC SYSTEM

PILOT REPORTED INSTRUMENT AIR PRESSURE WAS LOW AT 1700 RPM. UP ON TROUBLESHOOTING THE MECHANIC NOTICED ON INITIAL RUN UP PRESSURES WERE WITHIN LIMITS, AFTER ENGINE STARTED TO WARM UP THE PRESSURE STARTED TO DROP BELOW LIMITS. ON INSP THE VANES SHOW SOME WEAR. INSTALLED NEW PUMP, SYS WORKED NORMAL. NO PROBABLE CAUSE OR RECOMMENDATIONS AT THIS TIME.

2011FA0000116

BEECH

CONT

BEECH

STRUCTURE

CRACKED

2/18/2011

M35   

IO470*

 

 

RT LE FLAP

PERFORMED INSP IAW SAFETY COMUNIQUE NR 313. FOUND RT FLAP L/E CRACKED (ABOUT 1.5 INCH LONG) IN THE VICINITY OF THE "FLAP ACTUATOR BRACKET". FURTHER FOUND NOSE RIB CRACKED AS WELL. REMOVED FLAP FOR REPAIRS.

CA100809002

BELL  

HNYWL

 

BALANCE WEIGHT

SEPARATED

5/19/2010

204B

T5313BHNYWL

 

 

COOLER BLOWER

ACFT WAS IN CRUISE FLIGHT WHEN THE TRANSMISSION OIL PRESSURE WARNING LIGHT ILLUMINATED. PILOT CARRIED OUT AN UNSCHEDULED LANDING. AT THE TIME OF ENG SHUTDOWN, THE TRANSMISSION WAS SHOWING OVER 20 PSI. THE ENGINEER ONBOARD INSPECTED THE OIL COOLER BLOWER COMPARTMENT AND FOUND IT COVERED IN OIL. ENGINEER FOUND THAT ONE OF OIL COOLER FAN AND TURBINE ASSY BALANCE WEIGHTS HAD SEPARATED FROM THE FAN CAUSING AN OUT OF BALANCE CONDITION WHICH LED TO A FAILURE OF TRANSMISSION OIL COOLER LINE PN 204-040-747-001 DUE TO THE HIGH VIBRATIONS. A SERVICEABLE OIL COOLER BLOWER ASSY AND NEW OIL COOLER LINE WERE INSTALLED, THE ACFT WAS GROUND RUN AND LEAK CHECKED SERVICEABLE. TRANSMISSION WATER FILTER WAS INSPECTED AS A PRECAUTION AND NO DEBRIS WAS NOTED. WATER FILTER WAS ROUTINELY INSPECTED OVER THE NEXT SERIES OF FLIGHTS, AGAIN, NO DEBRIS NOTED. FAILURE IS BELIEVED TO HAVE BEEN CAUSED BY THE RIVET SECURING THE BALANCE WEIGHT TO THE FAN AND TURBINE FAILING DUE TO UNDETECTABLE CRACKS ON THE RIVET ITSELF. THE ENGINEER REPORTED ON THE PREVIOUS START, HE HAD FELT THE AREA FOR ROUGHNESS AND DETECTED NO ABNORMAL VIBRATIONS AT THAT TIME. THIS IS AN AREA THAT IS CHECKED BY FEEL DAILY AT RUN UP FOR BALANCE CONDITION AS BEARING FAILURE ON THE FAN AND TURBINE CAN HAPPEN, THIS HOWEVER IS THE FIRST FAILURE OF THIS KIND WE HAVE HAD.

CA100809003

BELL  

HNYWL

 

BEARING

DEFECTIVE

5/29/2010

204B

T5313BHNYWL

 

204011761001

TAIL ROTOR

DURING A FIRE MISSION, WITH THE BAMBI IN THE WATER GETTING FILLED ON A 100 FOOT LONG LINE, THE PILOT LOST AUTHORITY OF THE TAIL ROTOR CAUSING THE ACFT TO PERFORM 3 TO 4 TURNS CLOCKWISE. PILOT WAS ABLE TO GAIN CONTROL OF ACFT AND LAND SAFELY FOLLOWING PROCEDURE ON A NEARBY SAND RUNWAY. TAIL ROTOR CROSSHEAD BEARING PN 204-011-761-001 WAS LATER FOUND BEING THE CAUSE OF THE PROBLEM BY THE AME DURING INSP. THE BALLS CONTAINED IN CAGE OF 1 SIDE OF DUPLEX BEARING WERE FOUND DISPLACED WHICH CAUSED THE TAIL ROTOR CROSSHEAD TO BE STUCK. FOLLOWING THE INCIDENT, ACFT WAS INSPECTED AND THE FOLLOWING PARTS WERE INSTALLED, CROSSHEAD PN 204-011-711-001 IN O/H COND., PITCH CHANGE SHAFT, PN 204-010-742-009 IN INSP CONDITION, PITCH CHANGE QUILL, PN 204-010-740-005 IN INSP COND., T/R CHAIN PN 204-001-739-003 IN SERVICEABLE CONDITION, T/R CROSSHEAD DUPLEX BRG IN NEW CONDITION AND ACFT WAS INSP FOR IT`S AIRWORTHINESS. THE NEW T/R CROSSHEAD BEARING INSTALLED IS A NEW TYPE MODEL.

R29R20110228001

BELL  

 

 

DRIVE LINK

MISREPAIRED

2/28/2011

412EP

 

 

412010405111

MAIN ROTOR

BEARING IMPROPERLY STAKED IN DRIVE LINK ASSEMBLY. MAXIMUM GAP BETWEEN BEARING RACE AND LINK LUG IS .005". GAP MEASURED .015" WHEN RECIEVED FROM ABLE ENGINEERING & COMPONENT SERVICES IN PHEONIX, AZ. THIS IS THE SECOND DRIVE LINK FROM ABLE THAT HAS BEEN IMPROPERLY STAKED.

FOTR2019813715

BOEING

 

 

FRAME

MISINSTALLED

11/21/2010

727200

 

 

 

ZONE 200

BS 890 FRAME HAS FASTENER WITH NO ED IN WINDOW AREA, LT SIDE. CUTOUT DAMAGED AREA DIM .75" X .5' ON STA 890 FRAME IAW SRM 53-10-4 FIG 1. FABRICATED 2 EA DOUBLERS FROM 7075-0 .071 DIM. 11" X 3" PO 20198132 IAW SRM 53-10-4 FIG 1. HEAT TREATED PARTS TO 7075T6 IAW FORM FAS0115, REV 1. INSTALLED REPAIR PARTS IAW SRM 53-10-4, FIG 1.

FOTR2019813123

BOEING

 

 

HINGE

CRACKED

12/1/2010

727200

 

 

 

ZONE 200

MCD UPPER AFT MOST SEGMENT FUSELAGE SIDE AFT LOBE IS CRACKED. REMOVED MAIN CARGO DOOR AFT SEGMENT HINGE IAW FREIGHTER MM, FIG 5201B, REV F. FABRICATED NEW SECTION FROM MS20001-16-7200 PO 9002399, DIM 18" X 3.75" IAW FREIGHTER MM FIG 5201B REV F. LOCATED AND DRILLED NEW AFT HINGE SECTION IAW FREIGHTER MM FIG 5201B REV F. INSTALLED NEW SECTION IAW FREIGHTER MM FIG 5201B REV F.

FY4Y197M20110315

BOEING

 

 

SKIN

CORRODED

3/11/2011

727200

 

 

65246868

RT WING TE FLAP

HEAVY CORROSION ON RT WING INBD MIDFLAP UPPER EXTERNAL SURFACE, AT WBL128, FWD OF FLAP T/E ABOUT 22.5". ORIGINAL THICKNESS IS 0.054" AFTER CORROSION REMOVE, REMAIN THICKNESS IS 0" IAW SRM 57-50-1, PAGE 8, AREA ABOUT 1" X 1.3750". REPAIR METHOD SRM 57-50-4, FIG-8. CORROSION LEVEL WAS LEVEL 2.

FY4Y197M20110315A

BOEING

 

 

SPAR

CORRODED

3/11/2011

727200

 

 

65217912

RT WING

HEAVY CORROSION ON RT WING INBD MIDFLAP REAR SPAR LOWER CHORD AT WBL142, ORIGINAL THICKNESS 0.121". AFTER CORROSION REMOVED, THE REMAINED THICKNESS WAS 0.051", AREA WAS 3" X 1". IT'S BEYOND LIMITED IAW SRM 57-50-1, PAGE 8. REPAIR METHOD REF SRM 57-50-2, PAGE 9 AND 51-40-4 FIG 1. THE CORROSION LEVEL WAS LEVEL 2.

FY4Y197M20110315B

BOEING

 

 

BEAM

CORRODED

3/11/2011

727200

 

 

652418911

HORIZONTAL STAB

LT HORIZONTAL STAB TRAILING LOWER BEAM LOWER SURFACE STA96 TO 97 HAD EXFOLIATION CORROSION. ORIGINAL THICKNESS IS 0.120". AFTER CORROSION REMOVED, THE REMAINED THICKNESS WAS 0.078" AREA WAS 2.25" X 1.5". IT'S BEYOND LIMIT IAW SRM 55-10-1, PAGE 1, NOTE B. CORROSION LEVEL IS 2.

FY4Y197M20110315C

BOEING

 

 

BEAM

CORRODED

3/11/2011

727223

 

 

652418911

LT HORIZONTAL

LT HORIZONTAL STAB TRAILING LOWER BEAM UPPER SURFACE STA 66 TO 70 HAD EXFOLIATION CORROSION. ORIGINAL THICKNESS WAS 0.091". AFTER CORROSION REMOVED, THE REMAINED THICKNESS WAS 0.025", AREA WAS 4" X 1". IT'S BEYOND LIMITED IAW SRM 55-10-1, PAGE 1, NOTE B. CORROSION LEVEL WAS 2.

FY4Y20110315

BOEING

 

 

SPLICE

CORRODED

3/14/2011

727223

 

 

69185561

LT WING TE FLAP

THE EXFOLIATION CORROSION IS FOUND AT LT I/B MID FLAP CHORD SPLICE AT WBL 193 DURING 6C CHECK. THE ORIGINAL THICKNESS OF THE CHORD SPLICE IS 0.072”. AFTER BLENT OUT, THE DIMENSION OF THE CORROSION AREA IS 3" (LENGTH) X 1 (WIDTH) AND REMAINDER THICKNESS IS 0.039". IAW SRM 57-50-1 FIG 3, THE DAMAGE IS OUT OF LIMIT. THE CHORD SPLICE WILL BE REPLACED WITH NEW ONE.

FY4Y197M20110315D

BOEING

 

 

BEAM

CORRODED

3/11/2011

727223

 

 

65248912

HORIZONTAL STAB

RT HORIZONTAL STAB TRAILING LOWER BEAM SURFACE STA 220 TO 222 HAD EXFOLIATION CORROSION. ORIGINAL THICKNESS IS 0.105". AFTER CORROSION REMOVED, THE REMAINED THICKNESS WAS 0.065", AREA WAS 2.75" X 1". IT'S BEYOND LIMITED IAW SRM 55-10-1, PAGE 1, NOTE B. CORROSION LEVEL WAS 2.

FY4Y201103151

BOEING

 

 

SPAR

CORRODED

3/11/2011

727223

 

 

65217911

LT WING TE FLAP

THE EXFOLIATION CORROSION IS FOUND AT LT INBD MID FLAP AFT SPAR LOWER CHORD AT WBL 82, DURING 6C CHECK. THE ORIGINAL THICKNESS OF THE CHORD IS 0.125". AFTER BLENT OUT, THE DIMENSION OF THE CORROSION AREA IS 3" (LENGTH) X 1" (WIDTH) AND REMAINDER THICKNESS IS 0.083" IAW SRM 57-50-1, FIG 3, THE DAMAGE IS OUT OF ALLOWABLE LIMIT. REPAIR THE SPAR CHORD IAW SRM 57-50-2 FIG 5 & 51-40-2, FIG 1.

FY4Y197M20110315E

BOEING

 

 

SEAT TRACK

CORRODED

3/11/2011

727223

 

 

 

BS 640

DURING PERFORMED CPCP CARD NR C53-224-01 PART 1 OF 3 FOR MAIN DECK CARGO COM'P FLOOR STRUCTURE, THE SEAT TRACK AT STA BS 640+3 AND BS 640+10 LBL. 0 WAS FOUND LEVEL 2 CORROSION. REPAIR METHOD IAW SRM 53-10-5 FOR FURTHER PROCESSING.

FOTR2019813713

BOEING

 

 

FRAME

DAMAGED

11/21/2010

727223

 

 

 

ZONE 200

BS 950A, FRAME HAS FASTENERS WITH NO ED IN WINDOW AREA. LT SIDE. CUTOUT DAMAGED AREA DIM. .75" X .5" ON STA 950A FRAME LT IAW SRM 53-10-4, FIG 1 FABRICATED 2 EA DOUBLERS FROM 7075-0 .071, DIM 11" X 3" PO 20198132 IAW SRM 53-10-4 FIG 1. HEAT TREATED PARTS TO 7075T6 IAW FASI FORM FAS0115 REV 1, INSTALLED REPAIR PARTS IAW SRM 53-10-4, FIG 1.

FOTR2019813714

BOEING

 

 

FRAME

DAMAGED

11/21/2010

727223

 

 

 

ZONE 200

BS 930 FRAME HAS FASTENER WITH NO ED AT WINDOW AREA, LT SIDE. CUTOUT DAMAGED AREA DIM .75" X .5" ON STA 930 FRAME LT IAW SRM 53-10-4, FIG 1 FABRICATED 2 EA DOUBLERS FROM 7075-0 .071 DIM 11" X 3" PO 20198132 IAW SRM 53-10-4 FIG 1. HEAT TREATED PARTS TO 7075T6 IAW FASI FORM FAS0115 REV 1. INSTALLED REPAIR PARTS IAW SRM 53-10-4, FIG 1.

FOTR2021700805

BOEING

 

 

STRUCTURE

DAMAGED

1/25/2011

727223

 

 

 

NR 3 PYLON

NR 3 PYLON DAMAGED. REMOVED TITANIUM DOUBLER FROM NR 3 PYLON IAW SRM 51-30-2 AND EA 2708-5401 REV 1, LOCATED AND DRILLED NEW TITANIUM DOUBLER PN 69-18227-2, PO 20217102 IAW SRM 51-30-5 AND 51-30-6. FABRICATED 2 EA, FREEZE PLUGS FROM 15-5PH .375 PO 20217121 DIM .278" X .5" AND FABRICATED RETAINER PLATE FROM 15-5PH .100: PO 420961 DIM 1.1" X .5". FABED NEW FILLER FROM 2024T3 .040" PO 90010895 DIM 3.2" X 2.2" ALL IAW EA 2708-5401, REV 1. TITANIUM DOUBLER FREEZE PLUG RETAINER PLATE AND NEW FILLER INSTALLED IAW EA 2708-5401 REV 1.

FY4Y197M20110310

BOEING

 

 

SKIN PANEL

CORRODED

3/7/2011

727223

 

 

65C139133

ZONE 100

DURING PERFORMED 6C-CHECK FOUND FUSELAGE EXTERIOR SKIN CORRODED (LEVEL 2) AT BS 1066 BETWEEN S-27L AND S-28L, IAW SRM 53-30-1, PAGE 2A PENETRATED DEPTH OUT OF LIMIT.

FOTR2101904027

BOEING

 

 

SKIN

DAMAGED

2/25/2011

727225

 

 

 

ZONE 100

EVALUATE EXISTING LIGHTNING STRIKE REPAIR AT FUSELAGE SKIN STATION 296 BETWEEN STRINGER 26-25 LT. REMOVED BLIND FASTENER AT FUSELAGE SKIN STATION 296 BETWEEN STRINGER 26-25 LT IAW SRM 51-30-2. HFEC AREA IAW NDTM 51-00-00 FIGURE 23 PART 6 WITH NO DEFECTS NOTED. INSTALLED FASTENER IAW SRM 51-30-2. FASI NR 04027

FOTR2101904238

BOEING

 

 

SKIN

DAMAGED

2/25/2011

727225

 

 

 

ZONE 100

EVALUATE EXISTING LIGHTNING STRIKE REPAIR AT FUSELAGE SKIN STATION 506 BETWEEN STRINGER 24-25 LT. REMOVED BLIND FASTENER AT FUSELAGE SKIN STATION 506 IAW SRM 51-30-2. HFEC AREA IAW NDTM 51-00-00 FIGURE 23 PART 6 WITH NO DEFECTS NOTED. INSTALLED FASTENER IAW SRM 51-30-2.

FOTR2101904448

BOEING

 

 

SKIN

DENTED

2/25/2011

727225

 

 

 

ZONE 100

EVALUATE EXISTING DENT AT FUSELAGE SKIN STATION 364 BETWEEN STRINGER 23-24 RT. REMOVED PREVIOUS REPAIR FROM BS364 STR. 23-24 RT IAW SRM 51-30-2. FABRICATED NEW REPAIR DOUBLER FROM 2024T3 .071 PO 90010841 DIM. 8.5" X 11" AND FABRICATED NEW STRUCTURAL FILLER FROM 2024T3 .063 PO 90011114 DIM. 3.75" X 3" IAW SRM 53-30-3 FIG.3A AND ERA 2815-5301. INSTALLED DOUBLER AND FILLER IAW SRM 53-30-3 FIG. 3A AND 51-30-2.

FOTR2101904250

BOEING

 

 

SKIN

DAMAGED

2/25/2011

727225

 

 

 

ZONE 100

EVALUATE EXISTING LIGHTNING STRIKE REPAIR @ FUSELAGE SKIN STA. 720B+3 AND 702B+4 BETWEEN STR. 18-19 L/H.... REMOVED BLIND FASTENER @ FUSELAGE SKIN STA 720B+3 AND 720B+4 IAW B727 SRM 51-30-2. HFEC AREA IAW N727 NDTM 51-00-00 PART 6 FIGURE 23 WITH NO DEFECTS NOTED. INSTALLED FASTENER IAW B727 SRM 51-30-2. FASI NR 04250 AND 04251

FOTR2101904249

BOEING

 

 

SKIN

DAMAGED

2/25/2011

727225

 

 

 

ZONE 100

EVALUATE EXISTING LIGHTNING STRIKE REPAIR AT FUSELAGE SKIN STATION 720A BETWEEN STRINGER 18-19 LT. REMOVED BLIND FASTENER AT FUSELAGE SKIN STATION 720A BETWEEN STRINGER 18-19 LT IAW SRM 51-30-2. HFEC AREA IAW NDTM 51-00-00 FIGURE 23 PART 6 WITH NO DEFECTS NOTED. INSTALLED FASTENER IAW SRM 51-30-2. FASI NR 04249

FOTR2102212546

BOEING

 

 

SKIN

DENTED

3/14/2011

7272A1

 

 

 

BS 1336

EVALUATE EXISTING DENT ON FUSELAGE SKIN AT BS 1336 ABOVE STRINGER 26L. EVALUATED DENT AND FOUND TO BE OUT OF LIMITS IAW SRM 53-30-1, FIG 1, DETAIL 2. DEBONDED AND REBONDED SKIN IAW SRM 51-20-4, REMOVED DAMAGED AREA IAW SRM 51-40-2, FABRICATED REPAIR DOUBLER FROM .050 2024T3 PO 90011142, DIM 10" X 9.5" IAW SRM 53-30-2 AND 51-40-2. INSTALLED REPAIR DOUBLER AND REBONDED SKIN IAW SRM 51-30-2 AND 51-20-4.

FOTR2102212315

BOEING

 

 

SKIN

CRACKED

3/14/2011

7272A1

 

 

 

NR 2 SLAT

NR 2 SLAT LWR SKIN CRACKED AT INBD TRACK TO SKIN ATTACH FASTENERS. CUT OUT DAMAGED AREA DIM 3.3" X 5.55" IAW SRM 57-50-3, FIG 1. FABRICATED REPAIR DOUBLER FROM 7075T6 .080 PO 90011142 DIM 6.75" X 7.4" AND FILLER FROM 7075T6 .080 PO90011142 DIM 5.55" X 3.3" IAW SRM 57-50-3, FIG 1 AND 57-50-2 FIG 2 AND 51-20-1, FIG 2. INSTALLED REPAIR DOUBLER AND FILLER IAW SRM 57-50-3, FIG 1. FASI NR 12315.

FOTR2102212576

BOEING

 

 

TAB   

DEBONDED

3/15/2011

7272A1

 

 

 

AILERON

LT OTBD AILERON TAB HAS DISBOND ON INBD END. REMOVED DAMAGE ON AILERON INBD END DIM 7" X 3" IAW SRM 51-40-20, PAGE 12, PARA 7. FABRICATED REPAIR CORE IAW SRM 51-40-20, PAGE 14, PARA 8. USING DUR-5052-44-3/16 PO 9009476 DIM 7" X 3". BONDED CORE IAW SRM 51-40-20, PAGE 16, PARA 9. FABRICATED REPAIR DOUBLER USING 2024T3 .012 PO 9008354 DIM 8.5" X 4.5" IAW SRM 51-40-20, PAGE 14, PARA 8. BONDED DOUBLER IAW SRM 51-40-20, PAGE 59, PARA 20. CLEANED SEALED AND FINISHED REPAIR IAW SRM 51-40-20, PAGE 62, PARA 22.

FOTR2102212575

BOEING

 

 

TAB   

DEBONDED

3/15/2011

7272A1

 

 

 

LT WING AILERON

LT OTBD AILERON TAB HAS DISBOND ON OTBD END. REMOVED DAMAGE ON AILERON TAB DIM 2" X 2" IAW SRM 51-40-20, PAGE 12, PARA 7. FABRICATED REPAIR CORE IAW SRM 51-40-20, PAGE 14, PARA 8 USING DUR-5052-44-3/16 PO 9009476 DIM 2" X 2". BONDED CORE IAW SRM 51-40-20 PAGE 16, PARA 9. FABRICATED REPAIR DOUBLER USING 2024T3 .012 PO 9008354 DIM 3.5" X 3.5" IAW SRM 51-40-20, PAGE 14 PARA 8. BONDED DOUBLER IAW SRM 51-40-20, PAGE 59 PARA 20. CLEANED SEALED AND FINISHED REPAIR IAW SRM 51-40-20, PAGE 62, PARA 22.

FOTR2102212307

BOEING

 

 

SPAR

CRACKED

3/15/2011

7272A1

 

 

 

LT WING

NR 1 SLAT ACTUATOR OTBD MOUNT SUPPORT ON LT WING FRONT SPAR CRACKED. REMOVED CRACKED WEB FROM L/E LT WING SLAT STA 398.1 IAW SRM 51-30-2. FABRICATED NEW WEB FROM 7075T6 .063 PO 9009533 DIM 4.5" X 9" IAW SB 727-57-0130 FIG 1. INSTALLED REPAIR WEB IAW SB 727-57-0130, FIG 1 AND SRM 51-30-2.

FOTR2102212402

BOEING

 

 

SKIN

GOUGED

3/14/2011

7272A1

 

 

 

NR 5 SLAT RT

RT WING NR 5 SLAT T/E SKIN BY INBD HOOK IS GOUGED. CLEANED AREA ON NR 5 SLAT IAW MM12-40-00, FOUND AREA OF GOUGE TO BE OUT OF LIMITS IAW SRM 57-50-1, FIG 2. FRABRICATED REPAIR PLATE FROM 7075-T6, .125 PO 90095-66, MEA 6.5 X 3.1885 IAW SRM 57-50-3, INSTALLED DOUBLER AND TAIL HOOK, IAW SRM 51-30-2.

FOTR2102212349

BOEING

 

 

SKIN

DAMAGED

3/14/2011

7272A1

 

 

 

BS 400 S2-3R

DRILL STARTS IN FUSELAGE AT STR 2R STA 400. FOUND AREA TO HAVE A SMALL DELAMINAION ON TEAR STRAP AT STR 2R-3R, L1 = .5 PERCENT = 5 PERCENT, FOUND TO BE WITHIN LIMITS, IAW SRM 53-30-4, FIG 7. INSTALLED RIVETS IAW SRM 51-10-2, 53-30-4.

FOTR2102212485

BOEING

 

 

WEDGE

DEBONDED

3/14/2011

7272A1

 

 

 

RT WING TE FLAP

RT INBD MID FLAP T/E WEDGE, LWR INBD NR 1 TRACK IS DISBONDED. REMOVED DAMAGED AREA, SANDED, CLEANED AND PREPPED AREA IAW SRM 51-40-20 PARA NR 7, REPAIRED RT INBD MIDFLAP T/E WEDGE LWR NR 1 TRACK AREA BY HOT BONDING REPAIR IAW SRM 51-40-20, PARA NR 20.

FOTR2102212339

BOEING

 

 

SKIN

CRACKED

3/14/2011

7272A1

 

 

 

LT WING TE FLAP

LT WING OTBD FLAP, AFT FLAP HAS CRACK AT L/E, JUST INBD OF MOST OTBD TRACK. CUT OUT DAMAGED AREA DIM 1.2" X 1" ON LT WING OTBD FLAP L/E IAW SRM 57-50-4, FIG 9. FABRICATED REPAIR DOUBLER FROM 2024T3 .040 PO 90011142, DIM 7.1" X 7.3" AND FILLER DIM 1.2" X 1" FROM 2024T3 .040 PO 90011114 IAW SRM 57-50-4, FIG 9 AND 57-50-2, FIG 4. INSTALLED REPAIR PARTS IAW SRM 57-50-4, FIG 9 AND 51-30-2.

FOTR2102212361

BOEING

 

 

SEAT TRACK

CORRODED

3/14/2011

7272A1

 

 

 

ZONE 200

BL-O-SEAT TRACK CORRODED STA 610. REMOVED BL-O- SEAT TRACK STA 590-730 IAW SRM 51-30-2 FABRICATED NEW SEAT TRACK FROM 40456, 7178T6511 PO 9007703 DIM 120" IAW SRM 51-10-2, 51-30-5. INSTALLED SEAT TRACK IAW SRM 51-30-2.

FOTR2102212335

BOEING

 

 

TAB   

DEBONDED

3/14/2011

7272A1

 

 

 

LT WING AILERON

LT WING OTBD AILERON TAB IS DISBONDED AT 4 EA PLACES. REMOVED DAMAGED ON LT OTBD AILERON TAB 30" FROM OTBD END, DIM 7" X 4" IAW SRM 51-40-20-PAGE 12, PARA 7. FABRICATED REPAIR CORE IAW SRM 51-40-20, PAGE 14, PARA 8, USING DUR-5052-44-3/16-N-E ALUMINUM CORE PO 9009476 DIM 7" X 4". BONDED CORE IAW SRM 51-40-20 IAW SRM 51-40-20 PAGE 16, PARA 9. FABRICATED REPAIR DOUBLER USING 2024T3 .012 PO 9008354 DIM. 8.5" X 5.5" IAW SRM 51-40-20, PAGE 14, PARA 8. BONDED DOUBLER IAW SRM 51-40-20, PAGE 59, PARA 20. CLEANED, SEALED AND FINISHED REPAIR IAW SRM 51-40-20, PAGE 62, PARA 22. WEIGHT OF TAB POST REPAIR IS 4.0 LBS WITHIN LIMITS IAW SRM 51-80-6, FIG 1.

7AHR2011030803

BOEING

 

 

SKIN

DENTED

3/8/2011

737290C

 

 

 

ZONE 300

A DENT WAS FOUND ON THE RT HORIZ STABILIZER LOWER SURFACE BETWEEN STABILIZER STA 120.0 AND 129.0 JUST FORWARD OF THE REAR SPAR. A/Y RATIO DETERMINED THE DENT WAS OUT OF LIMITS. THIS AREA WAS THEN REPAIRED IAW SRM REF 55-10-3, FIG 8. NO OTHER DAMAGE WAS NOTED AT THIS LOCATION.

7AHR2011021801

BOEING

 

 

STRINGER

CORRODED

2/18/2011

737290C

 

 

BAC1498117

BS 344

DURING A C-CHECK, A VISUAL INSP REVEALED CORROSION ON STR 22 LT AT FUSELAGE BODY STA 344. A 20 IN SECTION OF STR WAS REPLACED IAW SRM REF 53-10-3. NO OTHER DAMAGE WAS NOTED AT THIS LOCATION.

7AHR2011021802

BOEING

 

 

STRINGER

CORRODED

2/18/2011

737290C

 

 

BAC1498117

ZONE 100

DURING C-CHECK, A VISUAL INSP REVEALED CORROSION ON STR 19 LT AT BODY STA 294.5. A 16 IN SECTION OF STRINGER WAS REPLACED IAW SRM REF 53-10-3. NO OTHER DAMAGE WAS NOTED AT THIS LOCATION.

2011FA0000121

BOEING

 

 

POWER SUPPLY

INOPERATIVE

2/22/2011

757236

 

 

20121

EMERGENCY LIGHTS

LT FWD EMERGENCY EXIT LIGHTS WILL NOT TEST (FIRST CLASS & LT 1 DOOR SLIDE LIGHTS). REPLACED POWER SUPPLY.

2011FA0000126

BOEING

 

AIRCRUISERS

SPRING

BROKEN

2/23/2011

757236

 

 

 

GIRT BAR

R1 DOOR ESCAPE SLIDE GIRT BAR HAS RT LEAF SPRING BROKEN.

2011FA0000120

BOEING

 

 

BULB

BURNED OUT

2/22/2011

757236

 

 

 

EMERGENCY LIGHT

EMERGENCY LIGHT AT OVERHEAD BIN 29L (ABC) INOPERATIVE.

2011FA0000118

BOEING

 

 

BATTERY PACK

UNSERVICEABLE

11/28/2010

757236

 

 

20121

EMERGENCY LIGHTS

OUTSIDE EMERGENCY LIGHTS ARE INOP AT DOORS 1L, 1R AND 4R.

2011FA0000122

BOEING

 

 

COVER

DAMAGED

2/22/2011

757236

 

 

 

L1 DOOR

DOOR 1, LT SIDE COVER FWD LATCH MOUNT DAMAGED.

2011FA0000119

BOEING

 

 

POWER SUPPLY

UNSERVICEABLE

2/22/2011

757236

 

 

20131A

EMERGENCY LIGHTS

FIRST CLASS EMERGENCY EXIT LIGHTS INOP, RT SIDE INCLUDING R1 SIDE LIGHT.

2011FA0000107

BOEING

 

 

CHARGER

MALFUNCTIONED

2/15/2011

757236

 

 

 

EMERGENCY LIGHTS

EMERGENCY LIGHT AT OVERHEAD BIN STA 530 INOP. R & R CHARGER IAW AMM 33-51-7. OPS CHECKS GOOD.

2011FA0000200

BOEING

 

 

ANGLE

CRACKED

3/11/2011

7673Y0

 

 

54110891

LT NACELLE

DISCOVERED PURSUANT COMPLIANCE WITH TASK CARD 767-57-594-00, LT WING AFT PYLON FAIRING INBOARD ANGLE T/E IS CRACKED IN RADIUS. NAC STA 408. CAUSE UNKNOWN. INSTALLED REPAIR ANGLES IAW DWG 54-11089-1 AND B767-300 SRM 51-40-02 AND EO RN 767-57-30.

2011FA0000167

CESSNA

 

 

BELLCRANK

BROKEN

3/10/2011

150F

 

 

0411258

ELEVATOR SYS

DURING ANNUAL INSP, FOUND ELEVATOR BELLCRANK PN 0411258 WITH A BEARING THAT CAME LOOSE FROM IT'S SWAGED MOUNTING. THE ONLY THING THAT KEPT IT FROM FALLING OUT COMPLETELY WAS THE FORK ROD THAT CONNECTS TO THE CONTROL COLUMN. ONCE THIS ROD WAS REMOVED THE BEARING FELL OUT. BEARING WAS NOT WORN, JUST POOR SWAGE/PRESS JOB. BELLCRANK PIVOT BEARING WAS OK. SLIGHT EXTRA PLAY AND CLICK NOISE COULD BE FELT PULLING BACK ON CONTROL COLUMN. BELLCRANK ASSY REPLACED.

2011FA0000221

CESSNA

CONT

 

CYLINDER

GALLED

3/24/2011

150L

O200A

 

TIST611DCA

ENGINE

DURING O/H, NEW STEEL CYLINDERS WERE INSTALLED AT CUSTOMERS REQUEST. THE STEEL CYL KIT TIST61.1DCA CONSISTED OF CYL ASSEMBLIES SN: 22070-146, 22070-141,22070-140 & 22070-133. AFTER REINSTALLATION OF THE ENG, AN ENG TEST RUN WAS PERFORMED WITH NORMAL RESULTS. 3 TEST RUNS OF 10 MINUTES WERE PERFORMED. ALL ENG INDICATIONS AND PRESSURES WERE NORMAL. THE ACFT WAS COWLED AND TEST FLIGHT BY CUSTOMER WAS ATTEMPTED. THE INITIAL RUN-UP WAS NORMAL, HOWEVER AS FULL POWER WAS APPLIED THE ENG BEGAN TO LOOSE POWER AND WAS EXTREMELY ROUGH AND THE TAKEOFF WAS ABORTED. DURING EXAM, NR 4 CYLINDER HAD ZERO COMPRESSION. THE INTAKE VALVE WAS STUCK IN THE OPEN POSITION. UPON FURTHER EXAM, ALL CYL INTAKE VALVES ERE GALLED AND STICKING. THE VALVES COULD NOT BE MOVED BY HAND. MFG WAS NOTIFIED AND STATED THAT THEY HAD RECENTLY RECEIVED REPORTS OF THIS AND THEY WERE REVIEWING THEIR DWGS. MFG DID AUTHORIZE TO REPAIR THE ISSUES, HOWEVER 4 CYL WERE REMOVED AND SENT BACK TO MFG. REPAIR STATION FEELS THAT THE ISSUE IS EITHER THE VALVE TO VALVE GUIDE CLEARANCE METAL INCOMPATIBILITY.

2011FA0000114

CESSNA

LYC   

 

LINE

LEAKING

1/18/2011

152   

O235*

 

040031158

FUEL SYSTEM

SMALL AMOUNT OF CORROSION ON UNDERSIDE OF FUEL LINE, RESULTED IN PIN-HOLE LEAK.

2011FA0000135

CESSNA

LYC   

 

SPARK PLUG

FRACTURED

2/12/2011

152   

O235L2C

 

REM37BY

ENGINE

A LOSS OF ENGINE POWER DURING FLIGHT. EXAMINATION OF ENGINE FOUND THAT THERE WAS A CATASTROPHIC FRACTURE AT THE FLANGE OF THE SPARK PLUG LEAVING THE COPPER GASKET WASHER STILL HELD IN PLACE ALONG WITH THE THREAD FROM THE SPARK PLUG BUT THE PLUG WAS COMPLETELY OUT OF THE CYLINDER WITH THE ELECTRODE AND CERAMIC INSULATOR STILL ATTCHED. UPON FURTHER INSPECTION, IT APPEARED THAT THE PLUG FAILED FROM FRACTURE ALL AT ONE TIME, AS IT DID NOT APPEAR THAT THERE WERE ANY PREVIOUS CRACKS.

CA100923007

CESSNA

LYC   

 

ENGINE

MAKING METAL

9/22/2010

152   

O235L2C

 

 

 

(CAN) LARGE AMOUNT OF METAL DISCOVERED IN ENGINE OIL FILTER DURING INP. ENGINE IS BEING SENT OUT TO ENGINE AMO TO INSPECT FOR DEFECTS AND REPAIR. TSO: 551 HRS. ENGINE IS ON A TC APPROVED MX SCHEDULE AND APPROVED TO BE ON-CONDITION. DISCOVERED DURING "ON CONDITION" INSPECTION.

2011FA0000166

CESSNA

LYC   

 

VALVE SPRING

BROKEN

10/22/2010

152   

O235L2C

 

 

ENGINE

WHILE ADJUSTING VALVE TAPPET CLEARANCE IAW MFG S.I. 1068A, FOUND INNER VALVE SPRING BROKEN ON CYLINDER NR 3 EXHAUST VALVE. NO OPERATIONAL PROBLEMS NOTED. COMPLIED WITH SB388C EXHAUST VALVE WOBBLE CHECK AND REPLACED BOTH BROKEN INNER AND UNBROKEN OUTER VALVE SPRINGS. VISUALLY INSPECTED ALL OTHER SPRINGS. SPRING WAS BROKEN NEAR THE BOTTOM (TOWARDS CYLINDER) WITHIN 1.5 TWIST.

CA100930010

CESSNA

LYC   

 

CABLE

FRAYED

9/30/2010

172M

O320E2D

 

505590401

SEAT STOP

THIS REEL IS PART OF A SECONDARY SEAT STOP KIT (SK210-174A) THAT WAS MARKETED IAW SEB 07-5 TO ALLEVIATE THE DANGER OF THE PILOT`S SEAT SLIDING BACK AND CAUSING ACFT CONTROL PROBLEMS. A MORE RECENT REVISION TO THE SB DEMANDED A CHANGE TO THE REEL ASSY TO ADDRESS CABLE RETRACTION PROBLEMS THAT WOULD CAUSE CABLE BENDING AND FAILURE. THIS PARTICULAR UNIT IS THE NEWER VERSION INTENDED TO OVERCOME THE CABLE PROBLEM BUT IT HAS FAILED AS WELL AFTER ONLY 384 HOURS. SUBMITTER SUGGESTS THAT MFG OFFER A REDESIGNED SET OF SEAT RAILS AND SEAT LOCKS SIMILAR TO THE SYS FOUND IN THEIR NEW ACFT TO TERMINATE AD CF87-15R2 AND US FAA AD 87-20-03R2 AND TO ELIMINATE THE NEED FOR TROUBLESOME SECONDARY STOPS.

2011FA0000171

CESSNA

LYC   

 

CARBURETOR

DAMAGED

3/10/2011

172M

O320E2D

 

MA4SPA

ENGINE

CARB WAS INSPECTED DUE TO ROUGH ENGINE OPERATION. UPON INSP IT WAS FOUND THAT 2 BOLTS THAT AFFIX THE 2 HALVES OF THE CARB TOGETHER WERE LOOSE ALLOWING A GAP OF APPROX .0265 INCH BETWEEN THE 2 HALVES OF THE CARB. THE BOLTS WERE STILL HELD IN PLACE BY THE TAB WASHERS. THE CONCLUSION IS THAT THE THREADS ON THE BOLTS AND OR CARB BODY WERE WORN TO SUCH A DEGREE THAT THE BOLTS WERE ALLOWED TO WORK UP OUT OF THE CARB. NOT RECOMMEND THAT THE BOLTS BE RETIGHTENED AND RETURNED TO SERVICE AS SUBSEQUENT FAILURE IS PROBABLE.

2011FA0000130

CESSNA

 

 

FLAP TRACK

CORRODED

2/19/2011

172R

 

 

05250012

ZONE 500

LEFT HAND FLAP TRACKS HAD EXFOLIATION CORROSION AT THE UPPER END OF THE TRACK.

2011FA0000141

CESSNA

 

 

CONTROL CABLE

FRAYED

3/1/2011

172S

 

 

0510105360

AILERONS

THE AILERON CABLE WAS FRAYED AND WORN SHOWING BROKEN STRANDS AT FUSELAGE STATION 65.33 WHERE THE CABLES PASS THOUGH THE 3 CEILING MOUNTED NYLON PULLEYS.

NX4R00006A

CESSNA

 

 

CONTROL CABLE

WORN

3/14/2011

172S

 

 

0510105308

ELEVATOR

DURING A 100 HR INSP, THE "UP" ELEVATOR CABLE WAS FOUND WORN AT FS-65.33. THE CABLE HAD MANY STRANDS WORN GREATER THAN 50 PERCENT THROUGH.

2011FA0000179

CESSNA

LYC   

 

PUMP

LEAKING

3/16/2011

172S

IO360L2A

 

LW15473

ENGINE

EVIDENCE OF OIL STREAMING DOWN BELLY TO TAIL. OIL NOTED DRIPPING FROM A DRAIN TUBE BELOW FIRE WALL. DRAIN TUBE CONNECTED TO AN OVERFLOW FITTING ON ENGINE MOUNTED MECHANICAL FUEL PUMP. PUMP R & R. PUMP CORE DISASSEMBLED & OIL FOUND LEAKING THROUGH 1ST OF 2 DIAPHRAGMS IN DUAL DIAPHRAGM PUMP. RUBBER MATERIAL COVERING BASE MATERIAL OF DIAPHRAGM FOUND FLAKING OFF. BASE MATERIAL POROUS & ALLOWED OIL THROUGH 1ST DIAPHRAGM INTO RING CHAMBER THAT ALLOWS OIL TO DRAIN OVERBOARD WITHOUT CONTAMINATION FUEL SIDE OF PUMP. FAILURE OF 2ND DIAPHRAGM WOULD ALLOW FUEL INJECTION TO BECOME CONTAMINATED. IN A 2 MONTH PERIOD, HAVE FOUND 2 PUMPS DRAINING OIL OVERBOARD. A 3RD ACFT FOUND WITH OIL CONTAMINATED FUEL INJECTION SYS.

2011FA0000143

CESSNA

CONT

 

MUFFLER

OBSTRUCTED

3/2/2011

182F

O470R

 

CEM0007

ZONE 100

THE STARBOARD MUFFLER BAFFLE CONE BROKE LOOSE FROM THE MUFFLER HOUSING AND OBSTRUCTED THE EXHAUST PIPE, CREATING BACK PRESSURE IN THE EXHAUST SYSTEM WHICH CAUSED THE ENGINE TO LOSE POWER. THE SUBSEQUENT FORCED LANDING ACCIDENT SUBSTANTUALLY DAMAGED THE AIRCRAFT AND AN AUTOMOBILE ON THE GROUND. THE FIVE PEOPLE IN THE AIRCRAFT AND IN THE CAR RECEIVED ONLY MINOR INJURIES.

JRUR2011030119HP

CESSNA

LYC   

 

GASKET

LEAKING

2/25/2011

182T

IO540AB1A5

 

 

PROPELLER HUB

RED DYE LEAKING FROM TWO SCREWS THAT ATTACH THE PROPELLER BALANCE RING TO THE HUB. THE PROPELLER HAS 640.1 HOURS SINCE OVERHAUL. THE PROPELLER HAS THE (OLD) STYLE HUB GASKET THAT REQUIRES A BLACK PERMATEX SEALANT TO BE USED.

2011FA0000140

CESSNA

LYC   

SLICK

DISTRIBUTOR BLK

BURNED

3/1/2011

182T

IO540AB1A5

 

 

MAGNETO

REMOVED LEFT MAGNETO FOR 500 HOUR INSPECTION AND FOUND DISTRIBUTOR BLOCK ASSEMBLY BURNED THROUGH AND PIECES FLOATING AROUND INSIDE MAGNETO. LARGE AMOUNT OF DUST COATED SURFACES AND BURNING EVIDENT ON COIL AND ROTOR HOUSING. CARBON BRUSH AND CAM ARE EXTREMELY WORN. ACCORDING TO THE ENGINE LOG THE MAGNETOS WERE R&R AT TACH TIME 1007.7 FOR 500HR INSPECTION ON 04/17/2009. DURING PRE-INSPECTION RUN-UP MAG DROP WAS NO MORE THAN 75-80RPM AT 1800RPM MIXTURE FULL RICH.

2011FA0000219

CESSNA

LYC   

SLICK

POINTS

CORRODED

3/22/2011

182T

IO540AB1A5

 

 

MAGNETO

AT THE LAST ANNUAL INSP, FOUND THE RT MAG POINTS PITTED AND REPLACED WITH A NEW SET OF M-3081 POINTS. CUSTOMER CALLED AS WAS HAVEING PROBLEMS WITH THE RT MAG, DEAD, NO SPARK. UPON INVESTIGATION, THE PROBLEM WAS THE POINTS TAB WAS BROKEN AND LAYING IN THE CASE. CALLED MFG, THEY TOLD ME THAT THAEY HAVE ABOUT 10 TO 15 FAILURES PER YEAR. ALSO TOLD ME THEY ARE WORKING ON A NEW DESIGN. THE TAB IS THE SPRING PART THAT MATES THE POINT TO THE BASE. THESE PARTS HAVE 6 HRS ON THEM SINCE NEW. HAVE BEEN DOING MAGS FOR 20+ YEARS AND HAVE NEVER HAD THIS HAPPEN. INSPECT POINT BEFORE INSTALLING.

2011F00042

CESSNA

PWA   

 

SPAR

BENT

2/22/2011

208   

PT6A114A

 

 

HORIZONTAL STAB

DURING PHASE 10 INSP FOUND THE HORIZ STAB FWD FACE OF THE MAIN SPAR BENT AND CRACKED IN THE CTR OF THE WEB AREA IN BETWEEN THE MAIN ATTACHMENT POINTS TO FUSELAGE STRUCTURE WITH THE STABILIZER REMOVED FROM THE ACFT TAILCONE.

2011F00038

CESSNA

PWA   

 

CAPACITOR

BURNED

2/12/2011

208B

PT6A114A

 

 

A/P COMPUTER

AUTOPILOT FAILED, PILOT SMELLED ELECTRICAL ODOR/FUMES. PILOT SAW SMOKE COMING FROM AUTOPILOT ENGAGE BUTTON. PILOT PULLED AND SECURED AUTOPILOT CIRCUIT BREAKER, SMOKE CLEARED IMMEDIATELY. AN INTERNAL INVESTIGATION OF THE AUTOPILOT COMPUTER REVEALED A BURNED CAPACITOR.

CA101018013

CESSNA

CONT

 

SWITCH

FAILED

10/15/2010

210L

IO520L

 

TA201TWB

LANDING LIGHT

SNAG: LANDING LIGHT SWITCH TO VERIFY, LANDING LIGHT SWITCH (1) PN: TA-201-TW-B. REPLACED NEW IAW SB SEB09-6 (DUE SPARKING COMING OUT THROUGH KNOB WHEN PUTTING SWITCH AT ON POSITION) CONNECTING, WIRES, TERMINALS, CHECKED OK SWITCH SECURED AND FUNCTIONAL CHECKED OK. (SWITCH OFF PN: TA-201-TW-B DATE INSTALLED JAN 12, 2010 AT 7281.7 HRS. )

2011F00063

CESSNA

 

 

TIRE

FLAT

3/3/2011

402A

 

 

600X6

NLG  

NOSE FLAT TIRE DUE TO FOD.

2011FA0000081

CESSNA

CONT

 

PROBE

MISMANUFACTURED

1/6/2011

421C

TSIO520N

 

400509

OIL TEMP

NEW INSTALLATION OF EDM-960 DIGITAL ENG MONITOR AS PRIMARY REPLACEMENT OF ALL FACTORY INSTALLED ENGINE INSTRUMENTATION IAW STC SA01828SE. SECOND INSTANCE, TO HAVE FOUND THE NEW PN 400509 OIL TEMP PROBE SUPPLIED WITH KIT WILL NOT FIT ORIGINAL FACTORY OIL TEMP PROBE LOCATION ON LT AND RT OIL COOLER ASSEMBLIES. ORIGINAL FACTORY OIL TEMP PROBES, PN 102-00002 AND ARE EQUIPPED WITH 7/16-20 STRAIGHT THREADS. THE PN 400509, OIL TEMP PROBE IS EQUIPPED WITH 5/8-18 STRAIGHT THREADS. AN ALTERNATE OIL TEMP PROBE PN 400505 IS EQUIPPED WITH 3/8-24 PIPE THREADS AND ALSO FAILS TO FIT THIS INSTALLATION IN THE FACTORY OIL TEMP LOCATIONS. SUGGEST MFG OIL TEMP PROBES OF APPROPRIATE SIZE AND THREAD PITCH FOR INSTALLATION IN ACFT UNDER THEIR CURRENT AML OR GET APPROVAL FROM THE MFG TO SAMPLE OIL TEMP AS A PRIMARY INDICATION FROM AN ALTERNATE LOCATION ON THE ENGINE WHICH THEIR CURRENT PROBES WILL FIT.

2011FA0000178

CESSNA

WILINT

 

PRECOOLER

SPLIT  

3/2/2011

525A

FJ44

 

99144024

BLEED AIR

CREW REPORTED A 50 DEGREE TEMP SPLIT IN FLIGHT. FOUND THE RT PYLON PRE-COOLER SPLIT AT SEAMS. RESULTING IN BLEED AIR LEAK INSIDE THE PYLON WHICH CAUSED FAILED CONDUCTIVITY TEST RESULTS OF THE PYLON AND FUSELAGE SKINS.

2011FA0000128

CESSNA

 

CESSNA

BEARING

LOOSE

2/24/2011

525B

 

 

63420113

NLG  

HYDRAULIC LIGHT FLASHED ON AND OFF WITH LANDING GEAR CYCLING AND GEAR UNSAFE LIGHT. FOUND NOSE GEAR UPLOCK SWITCH OUT OF ADJUSTMENT,(ADJUSTED) OPS CHECK GOOD ON JACKS. REPETE SQUAWK ON NEXT FLIGHT. FOUND NOSE GEAR STRUT EXTENSION BEYOND LIMITS. DISASSEMBLED NOSE GEAR, FOUND BEARING PN 6342011-3 LOOSE, ALSO FOUND 4 EA. RETAINING SET SCREW PN NAS1081-3B4 NOT INSTALLED. WHICH CAUSED BEARING TO BACK OFF AND LEGTHEN THE STRURT EXTENSION, TO GENERATE THE MALFUNCTION. SECTION 32-20-00, FIGURE 1001, ITEMS 231, 232. OF 525B IPC.

2011FA0000106

CESSNA

PWA   

BFGOODRICH

BEARING

BROKEN

2/15/2011

560CESSNA

JT15D5

99121254

 

STARTER GEN

CREW NOTICED A VIBRATION IN CRUISE. IDENTIFIED ELECTRICAL POWER LOSS IN RT STARTER/GENERATOR. I SOLATED STARTER/GENERATOR. NO FURTHER PROBLEMS EXPERIENCED DURING THE FLIGHT. RESEARCH REVEALED THE STARTER/GENERATOR, O/H, HAD THE SAME FAILURE PRIOR TO BEING OVERHAULED. BECAUSE OF THE CALENDAR TIME, IT WASN'T POSSIBLE TO TRACE THE COMPONENT HISTORY OF THE BEARINGS, VENDOR, ETC. STARTER/GENERATOR RETURNED FOR FURTHER EVALUATION.

2011FA0000236

CESSNA

 

 

STRUCTURE

CORRODED

3/30/2011

680CE

 

 

692251011

LT WING L/E

DURING REPAIR OF THE LT WING L/E, FOUND CORROSION IN AN AREA THAT IS NOT ACCESSIBLE WITHOUT REMOVING RIVETS AND THE DIFFUSER TUBE. THESE AREAS WERE BLENDED AND PRIMERED USING REPAIR DATA FROM MFG. THIS SITUATION WOUDL HAVE CONTINUED TO CORRODE WITHOUT ANY INDICATION HAD MX NOT BEEN NEEDED IN THIS AREA FOR OTHER REASONS.

2011FA0000134

CESSNA

 

 

CONNECTOR

DAMAGED

2/9/2011

680CE

 

 

 

RT WING

DURING FUEL TANK INSPECTIONS, FINDING ELECTRICAL BLANKING PINS IN WING ROOT OF FUEL TANKS. PINS FALLING OUT OF PLUGS PREVIOUSLY INSTALLED DURING ACFT MFG.

2011FA0000234

CESSNA

CONT

 

CONTROL CABLE

OUT OF POSITION

2/21/2011

A185F

IO520D

 

 

MIXTURE

DURING THE FIRST FLIGHT TEST AFTER ENGINE INSTALLATION, THROTTLE CONTROL CABLE STARTED TO MOVE HARD AND SEEMED TO BE BINDING. PILOT WAS UNABLE TO MAKE SMALL ADJUSTMENTS WITH THROTTLE. THE TEST FLIGHT WAS STOPPED AND ACFT LANDED ITHOUT ANY PROBLEM. ENGINE COWLING WAS REMOVED. THE THROTTLE CONTROL CABLE WAS DISCONNECTED AT ATTACHING ARM ON THROTTLE CONTROL. INSP OF THROTTLE CONTROL CABLE REVEALED THAT THE CABLE WORKS AND PERFORMS NORMAL. THE BINDING IS COMING FROM THE AIR THROTTLE CONTROL, MIXTURE ADJUSTING ROD WAS REMOVED TO ISOLATE THE BINDING. THE BINDING WAS COMING FROM THE THROTTLE BUTTERFLY INTERCONNECT SIDE OF THE MIXTURE METERING VALVE. SINCE THE ENGINE WAS UNDER WARRANTY, A CALL WAS PLACED TO MFG TO ADVISE THEM OF THE PROBLEM. REPLACED AIR THROTTLE CONTROL IAW MFG WARRANTY. TT ON PART WAS 0.60 HOURS SINCE REBUILT. AIR THROTTLE CONTROL WAS NOT DISASSEMBLED FOR FURTHER INVESTIGATION, IT WAS RETURNED TO MFG. END.

CA101101002

CESSNA

LYC   

 

PISTON

CORRODED

10/22/2010

T206H

TIO540AJ1A

 

LW10545S

ENGINE

AFTER REMOVING AN ENGINE CYL TO REPLACE AN EXAUST STUD, IT WAS NOTICED THAT THE PISTON HAD CORROSION ON IT. ALL CYLINDERS WERE REMOVED AND PISTONS INSPECTED. CORROSION WAS FOUND ON ALL PISTONS. THE CYLINDERS WERE REPAIRED AND NEW PISTONS AND RINGS INSTALLED.

2011FA0000153

CESSNA

 

 

THROTTLE CONTROL

LOOSE

2/10/2010

TU206G

 

 

98630562

ENGINE

THROTTLE CONTROL ASSEMBLY - ON AFT END OF THE CONTROL, THE PILOT END OF THE PUSH/PULL CONTROL - THE THREADED ALUMINUM ATTACH FITTING IS LOOSE ON THE STEEL SLEEVE, NORMALLY A TIGHT FIT. ON THE FWD END OF THE CONTROL - THE ENGINE ATTACHMENT END , THE SLEEVE IS VERY LOOSE, POSSIBLE TO PULL IT OUT FROM WITHIN THE CRIMPED PORTION. IF THIS SLEEVE WERE TO COME OUT OF THE CRIMP, LOSS OF THROTTLE AUTHORITY IS POSSIBLE. ALSO, THE CAUSE OF THE INSP AND SUBSEQUENT REMOVAL OF THE CONTROL FROM SERVICE WAS THE VERY STIFF - JERKY MOVEMENT OF THE CONTROL. THE PILOTS REPORTED INABILITY TO ACHIEVE A SMALL, SMOOTH POWER CHANGE ON APPROACH.

2011FA0000174

CESSNA

CONT

 

PLUG

FAILED

2/23/2011

U206G

IO520F

 

633189

CRANKSHFT

THE ENGINE WAS REMOVED FROM THE ACFT AT ENG TT 2157.4 (AIRFRAME TT 4652.7) FOR REPAIR DUE TO LOW OIL PRESSURE. THE CRANKSHAFT PN 64134, SN 109903N WAS SENT TO MFG FOR ULTRASONIC INSP, BALANCE, POLISHED AND RECERTIFIED. THE CRANKSHAFT WAS RETURNED BY MFG AS SERVICEABLE 343.2 HRS LATER AT ENGINE TT 2500.6 A O/H PROP GOVERNOR WAS INSTALLED DUE TO REPEATED PROP SURGES. THE PROP SURGES CONTINUED, SO AT ENG TT 2520.7 WE REMOVED THE PROP TO BE SENT TO A PROP REPAIR FACILITY FOR INSP AND POSSIBLE REPAIR. AT THIS TIME DIFFERENT MFG PROPELLER WAS INSTALLED ON THE ACFT. DURING POST INSTALLATION RUN-UP THE DIFFERENT MFG PROPELLER WOULD NOT CYCLE FROM LOW PITCH TO HIGH PITCH. REMOVED THAT PROP AND THE PN 633189 OIL CONTROL PLUG THAT DIRECTS OIL THROGH THE INSIDE OF THE CRANKSHAFT TO THE PROPELLER FELL OUT OF THE END OF THE CRANKSHAFT. THE LOOSE PLUG WAS OBVIOUSLY LEAKING OIL PRESSURE AND MAY HAVE BEEN THE PROP SURGE PROBLEM. WHEN WE RECEIVED A NEW 633189 PLUG . WE NOTICED THAT THE CTR HOLE THAT FACES THE CRANKSHAFT WAS THREADED: THE HOLE IN THE PLUG THAT FELL OUT OF THE CRANKSHAFT WAS NOT THREADED; THE PROP SURGES CEASED AFTER THE INSTALLATION OF THE NEW PLUG AND THE DIFFERENT MFG PROP.

2011FA0000113

CIRRUS

CONT

 

AIR FILTER

SEPARATED

2/17/2011

SR22

IO550*

 

BA24  

ZONE 400

THE AIR FILTERS, PN BA-24, USED ON THESE ACFT ARE 12 MONTH/200 HR REPLACE ITEMS. THESE FILTERS ARE FOAM CYLINDRICAL SHAPED MADE FROM A SHEET OF FOAM ROLLED AND GLUED TO FORM THEIR SHAPE. ALMOST EVERY ACFT THAT HAS BEEN SEEN WITH THIS FILTER INSTALLED, THE FILTER IS SEPARATING AT THE GLUE LINE, ALLOWING UNFILTERED AIR TO ENTER THE INTAKE. THESE FILTERS DO NOT LAST FOR THE DURATION OF THEIR INTENDED LIFE.

2011FA0000137

CIRRUS

CONT

 

CAMSHAFT

BROKEN

1/27/2011

SR22

IO550N

 

654084

ENGINE

DURING CRUISE PHASE OF FLIGHT AT NIGHT, PILOT REPORTED THAT THE AIRCRAFT ENGINE SURGED AND LOST POWER. ATTEMPTED TO RESTART WITH NO SUCCESS. PILOT DEPLOYED THE AIRCRAFT PARACHUTE AND LANDED IN A FIELD. ON ENGINE TEARDOWN, IT WAS NOTED THAT THE CAMSHAFT HAD BROKEN FORWARD OF THE CAMSHAFT GEAR.

V0XR413Y030511002

CNDAIR

 

 

CROSSBEAM

CORRODED

3/5/2011

CL6002C10

 

 

 

ZONE 100

RT WEB AT 280.00 CROSSBEAM CORRODED. R & R SILL FS 280.00 RT IAW REO 670-53-21-659 AND SRM 51-42-06 AND 51-42-13.

V0XR413Y030511004

CNDAIR

 

 

FITTING

CORRODED

3/5/2011

CL6002C10

 

 

 

ZONE 100

STA 319, RBR 4 GALLEY FITTING CORRODED. R & R GALLEY FITTING IAW SRM 51-42-21.

V0XR413Y030511005

CNDAIR

 

 

FITTING

CORRODED

3/5/2011

CL6002C10

 

 

 

ZONE 100

STA 286, RBL 18, GALLEY FITTING CORRODED. R & R GALLEY FITTING IAW SRM 51-42-21.

V0XR413Y030511006

CNDAIR

 

 

FITTING

CORRODED

3/5/2011

CL6002C10

 

 

 

ZONE 100

STA 296, RBR 4, GALLEY FITTING CORRODED. R & R GALLEY FITTING FS 294, RBL 4 IAW SRM 51-42-21.

V0XR413Y030511007

CNDAIR

 

 

ANGLE

CORRODED

3/5/2011

CL6002C10

 

 

 

ZONE 100

FWD RT SILL STA 300 SPLICE ANGLE CORRODED. R & R RT SILL STA 300 SPLICE ANGLE IAW SRM 51-42-06.

V0XR413Y030511008

CNDAIR

 

 

SILL

CORRODED

3/5/2011

CL6002C10

 

 

 

ZONE 200

AFT CARGO LOWER DOOR SURROUND SILL CORRODED. R & R LOWER SILL ON AFT CARGO DOOR IAW SRM 53-61-23, 51-23-00, 51-24-38, 51-42-06, 51-42-13, 51-42-15, 51-42-21.

V0XR413Y030511009

CNDAIR

 

 

BULKHEAD

CORRODED

3/5/2011

CL6002C10

 

 

 

ZONE 200

RT LOWER BULKHEAD CORRODED AT FS 280.00. R & R RT LWR BULKHEAD FS 280.00 IAW SRM 53-11-10/REO 670-53-11-052.

V0XR413Y030511010

CNDAIR

 

 

BULKHEAD

CORRODED

3/5/2011

CL6002C10

 

 

 

ZONE 200

LT LOWER BULKHEAD ST 280.00 HAS CORROSION. REMOVED AND INSTALLED LWR BULKHEAD LT STA 280.00 IAW RE0 670-53-11-052/SRM 51-24-21/ SRM 53-11-10.

V0XR413Y030511011

CNDAIR

 

 

ANGLE

CORRODED

3/5/2011

CL6002C10

 

 

 

ZONE 200

SERVICE DOOR ANGLE, MIDCAP AND ANGLE CLIP HAVE EXFOLIATION CORROSION THROUGH OUT EACH. R & R DOOR ANGLE, MIDCAP AND ANGLE CLIP IAW SRM 51-42-06 AND SRM 51-42-21.

V0XR413Y030511013

CNDAIR

 

 

ANGLE

CORRODED

3/5/2011

CL6002C10

 

 

 

ZONE 800

PAX DOOR LOWER STEP ANGLE HAS SIGNS OF CORROSION. REMOVED AND INSTALLED NEW ANGLE BOTTOM IAW SRM 52-11-04, 51-42-06 AND 51-42-11.

V0XR413Y030511014

CNDAIR

 

 

SEAL

DETACHED

3/5/2011

CL6002C10

 

 

 

OVR WING SLIDE

RT SIDE EMERGENCY OVERWING EXIT DOOR, PRESSURIZATION SEAL IS UNGLUED AT BOTTOM FRAME. RESECURED RT SIDE EMERGENCY OVERWING EXIT DOOR SEAL IAW AMM 52-21-07-400-801.

V0XR413Y030511015

CNDAIR

 

 

INSULATION

SATURATED

3/5/2011

CL6002C10

 

 

 

ZONE 800

RT EMERGENCY EXIT DOOR HAS WET INSULATION BAGS. R & R INSULATION BLANKET IN LT OVERWING EMERGENCY EXIT DOOR IAW AMM 25-82-02-400-803.

V0XR413Y030511016

CNDAIR

 

 

LATCH

CORRODED

3/5/2011

CL6002C10

 

 

 

ZONE 800

LT OVERWING EXIT DOOR OPEN HANDLE BRACKETS AND LATCH MOUNT HARDWARE CORRODED. R & R HARDWARE ON OPEN HANDLE BRACKETS AND LATCH MOUNT IAW AMM 52-21-02-000-801.

V0XR413Y030811017

CNDAIR

 

 

SUPPORT BEAM

CORRODED

3/8/2011

CL6002C10

 

 

 

ZONE 100

STA 333, SUPPORT BEAM HAS CORRODED. STA 333, LBL 14.81 TO LBL 20.0 REPAIRED IAW REO 670-53-21-656.

V0XR413Y030511012

CNDAIR

 

 

CABLE

WORN

3/5/2011

CL6002C10

 

 

 

ZONE 800

PAX DOOR PRESSURE VENT FLAP CABLE WORN. REMOVED OLD CABLE AND INSTALLED NEW ICE BREAK CABLE IAW AMM 52-11-15-400-802.

V0XR413Y021811014

CNDAIR

 

 

ANGLE

CORRODED

2/18/2011

CL6002C10

 

 

 

ZONE 100

FORWARD FUS SERVICE DOOR LOWER SECTION, MOUNTING ANGLE CORRODED. R & R ANGLE MOUNTING PN SH 670-31996-3, BATCH 106807 IAW ARM 53-21-23, SRM 51-42-06, SRM 51-42-02 AND SRM 51-23-00.

V0XR413Y021811013

CNDAIR

 

 

ANGLE

CORRODED

2/18/2011

CL6002C10

 

 

 

ZONE 100

PAX ENTRY DOOR MID CAP ANGLE CORRODED. REMOVED AND INSTALLED NEW MID CAP ANGLE. PN SH670-31825-7 IAW SRM 53-21-23 AND SRM 51-41-02.

V0XR413Y021811016

CNDAIR

 

 

SILL

CORRODED

2/18/2011

CL6002C10

 

 

 

ZONE 200

AFT CARGO BAY , DOOR FRAME LOWER SILL HAS EXFOLIATION CORROSION. AFT CARGO BAY DOOR FRAME LOWER SILL, R & R IAW SRM 53-61-23, HOLES IAW 51-40-11, RIVETS IAW 51-42-06, HI LOKS IAW 51-42-20, BLIND FASTENERS IAW 51-42-15, ALODINE IAW 51-21-16, PRIMER IAW 51-25-06, PAINT IAW 51-25-21, NUT PLATES IAW 51-45-00, AND SEALANT IAW 51-23-00.

V0XR413Y031711008

CNDAIR

 

 

FITTING

CORRODED

3/17/2011

CL6002C10

 

 

 

ZONE 200

PASSENGER DOOR THRESHOLD FWD CLOSING FITTING IS CORRODED. R & R FITTING CLOSING ON PASSENGER DOOR IAW SRM 53-21-23, 51-42-06 AND 51-40-11.

V0XR413Y031711009

CNDAIR

 

 

ANGLE

CORRODED

3/17/2011

CL6002C10

 

 

 

ZONE 200

PASSENGER DOOR THRESHOLD KICK ANGLE IS CORRODED. R & R KICKPLATE ANGLE ON PASSENGER DOOR IAW SRM 53-21-23, 51-42-06 AND 51-40-11.

V0XR413Y031711006

CNDAIR

 

 

ANGLE

CORRODED

3/17/2011

CL6002C10

 

 

 

ZONE 200

PASSENGER DOOR THRESHOLD MIDCAP CORRODED. R & R ANGLE MID CAP IAW SRM 53-21-23, 51-40-11 AND 51-42-01 ON THE PASSENGER DOOR.

V0XR413Y031711007

CNDAIR

 

 

ANGLE

CORRODED

3/17/2011

CL6002C10

 

 

 

ZONE 200

SERVICE DOOR THRESHOLD MOUNT ANGLE IS CORRODED. R & R THRESHOLD MOUNT ANGLE IAW SRM 51-42-06-001-001-A01 AND 51-42-21-001-001-A01.

N6WA20110311

CNDAIR

 

 

TRIM PANEL

LOOSE

3/14/2011

CL6002C10

 

 

 

EMERGENCY EXIT

RT OVERWING EMERGENCY EXIT TRIM LOOSE. RESECURED TRIM IAW AMM 52-21-00.

V0XR413Y031711010

CNDAIR

 

 

STOP FITTING

DETERIORATED

3/17/2011

CL6002C10

 

 

 

ZONE 200

AFT CARGO DOOR UP STOP BLOCKS DETERIORATED. REPLACED BOTH FWD AND AFT, UPPER AFT CARGO DOOR STOPS IAW AMM 52-31-23-400-801.

V0XR413Y031711002

CNDAIR

 

 

SILL

CRACKED

3/17/2011

CL6002C10

 

 

 

ZONE 100

FWD CARGO DOOR SILL PLATE DAMAGED. REPLACED FWD CARGO DOOR SILL PLATE IAW AMM 25-52-01.

V0XR413Y031711011

CNDAIR

 

 

SHROUD

CRACKED

3/17/2011

CL6002C10

 

 

 

CARGO DOOR

CARGO DOOR SHROUD IS CRACKED. R & R CARGO DOOR SHROUD IAW SRM 51-73-00-001-001.

V0XR413Y031711012

CNDAIR

 

 

DRAG ANGLE

CRACKED

3/17/2011

CL6002C10

 

 

 

PAX DOOR

PASSENGER DOOR AFT DRAG ANGLE CRACKED. REPAIRED PASSENGER DOOR DRAG ANGLE AFT SIDE IAW SLM 52-11-04.

V0XR413Y031711004

CNDAIR

 

 

CONNECTOR

CORRODED

3/17/2011

CL6002C10

 

 

 

PAX DOOR

BACK SHELL ON PASSENGER DOOR CONNECTOR IS CORRODED. R & R BACKSHELL ON PASSENGER DOOR CONNECTOR IAW SRM 20-24-00.

V0XR413Y031711005

CNDAIR

 

 

SILL

CORRODED

3/17/2011

CL6002C10

 

 

 

ZONE 200

AFT BAGGAGE BAY LOWER DOOR SILL HAS EXFOLIATION CORROSION THROUGHOUT. R & R AFT BAGGAGE BAY LOWER SILL IAW SRM 51-41-00, 51-42-00, 51-21-16 AND 51-25-21.

2011FA0000131

CUBCFT

LYC   

 

CARBURETOR

INOPERATIVE

2/10/2011

CC18180

O360C4P

 

AV109236

ENGINE

ACFT HAD FLOWN FOR 2+ HOURS IN THE MORNING. AFTER LUNCH, PILOTS TOOK ACFT AGAIN AND ABOUT 30 MINUTES INTO THE FLIGHT, THE ENGINE STARTED TO RUN ROUGH. CARB HEAT WAS APPLIED AND MADE NO DIFFERENCE TO ROUGHNESS. PILOTS RETURNED TO BASE AND MX INSPECTED ACFT AND FOUND NOTHING OBVIOUS. WHILE PERFORMING GROUND RUNS, MX FOUND THAT YOU COULD ONLY ADVANCE THE THROTTLE VERY, VERY SLOWLY OR THE ENGINE WOULD DIE. WHILE RUNNING THE ENGINE RPM VARIED 200-300 RPM. REPLACED CARBURETOR WITH A SERVICEABLE UNIT. GROUND RUNS WERE GOOD.

CA100923008

DHAV

PWA   

 

FITTING

CRACKED

9/21/2010

DHC2MKI

R985AN14B

4930

58S927R58S926L

FLOAT STRUT

WHILE CONDUCTING A 100 HR INSP IT WAS IDENTIFIED THAT 2 LOWER FLOAT STRUT FITTINGS WERE CRACKED. THESE FITTINGS ARE INSPECTED EVERY 100 HRS AND PREVIOUS INSPECTIONS DID NOT IDENTIFY ANY ABNORMALITIES. THE FITTINGS WERE REPLACED WITH NEW UNITS. ALL OTHER FITTINGS WERE INSPECTED AND NO FURTHER DEFECTS WERE NOTED.

CA100929009

DHAV

PWA   

 

BEARING CAGE

DAMAGED

9/27/2010

DHC2MKI

R985AN14B

40418

21401200

MAIN WHEEL

MAIN WHEEL BEARING IS OF A NEW SLIMMER DESIGN. PRONE TO PREMATURE FAILURE. UPON INSP, WHEEL BEARING FOUND WITH A SEVERLY DAMAGED CAGE AND RACE, SOME ROLLERS BADLY DAMAGED. THIS IS THE SECOND BEARING OF THIS NEW DESIGN THAT HAS FAILED LIKE THIS.

CA100927007

DIAMON

CONT

 

FORK

CRACKED

9/26/2010

DA20C1

IO240B

203220000

2032200800

NLG  

BOTH ARMS ON FORK THAT LEAD TO THE WHEEL, APPROX 1.5 INCHES FROM WHEEL THROUGH BOLT, CRACKED ON UPPER AND LWR SURFACES.

U43R2010AF0000205

DIAMON

 

 

FORK

BROKEN

2/14/2011

DA40

 

 

40006

NLG  

THIS ACFT WAS THE FIRST INCIDENT THAT WAS THOUGHT TO HAVE BEEN PILOT ERROR. THE SECOND INCIDENT THE NOSE WHEEL SEPARATED FROM THE AIRPLANE. BOTH INCIDENTS HAPPENED WITH IN ABOUT 90 DAYS. TO BE ON THE SAFE SIDE, WE PERFORMED AN NDI (EDDY CURRENT) OF ALL 20 FORKS THAT WERE ON OUR ACFT, PLUS THE 6 THAT WERE IN SUPPLY (NEW). OF THE 26 NOSE FORKS THAT HAD BEEN NDI'D, 4 WERE RETURNED CONDEMED. THE AVERAGE TIME IN SERVICE, 530 HOURS. THE AVERAGE NUMBER OF LANDINGS 419.

CA100922001

DIAMON

LYC   

 

DOOR

DEPARTED

9/15/2010

DA40

IO360M1A

 

DA4522100003

CABIN

REPORT STATES REAR DOOR DEPARTED ACFT APPROX 10 MINUTES INTO FLIGHT, ACFT JUST LEVELED AT 3500` FROM 2000`. INSTRUCTOR AND STUDENT BOTH STATE NO PREVIOUS ANNUNCIATION UNTIL SHORTLY BEFORE DOOR DEPARTED. DOOR NOT RECOVERED. FAA INVESTIGATING THIS OCCURRENCE. MANDATORY SB40-070 HAD NOT BEEN COMPLIED WITH AT TIME OF OCCURRENCE. ONLY MINOR COSMETIC DAMAGE REPORTED ON ACFT.

2011FA0000138

DIAMON

 

 

RUDDER PEDAL

CRACKED

2/28/2011

DA42

 

 

DA427233700

ZONE 100

DURING PRE-FLIGHT, CREW NOTICED THAT THE RUDDER PEDAL APPEARED TO BE CROOKED, AT A DIFFERENT ANGLE RELATIVE TO THE OTHER PEDAL. MAINTENANCE PERSONNEL DISCOVERED THAT THE RUDDER PEDAL, P/N-DA4-2723-37-00 WAS CRACKED APPROXIMATELY 2 INCHES LONG WHERE THE BRAKE CYLINDER ACTUATING WEB IS WELDED TO THE HORIZONTAL TUBE. TWO OTHER AIRCRAFT IN THIS FLEET OF TEN HAD SIMILAR CRAKED PEDALS. IN TOTAL THERE WERE 4 CRACKED PEDALS.

NX4R20110301001

DIAMON

 

 

PEDAL

CRACKED

3/1/2011

DA42

 

 

DA427233500

ZONE 100

DURING PREFLIGHT, THE FLIGHT CREW NOTICED THAT THE RUDDER PEDALS WERE NO LONGER SYMMETRICAL COMPARED TO EACH OTHER. A MAINTENANCE TECHNICIAN INSPECTED THE CO-PILOT’S LH PEDAL (P/N-DA4-2723-35-00) AND NOTICED THAT THE VERTICAL WEB THAT CONNECTS THE PEDAL TO THE BRAKE MASTER CYLINDER ROD HAD TORN AT THE WELDED INTERSECTION OF THE TUBE THAT IT IS WELDED TO. THE TEAR/CRACK IN THE HORIZONTAL PEDAL PIVOT TUBE INDICATES A TORSIONAL FAILURE OF THAT TUBE.

NX4R20110301002

DIAMON

 

 

PEDAL

CRACKED

3/1/2011

DA42

 

 

DA427233500

ZONE 100

DURING PREFLIGHT, THE FLIGHT CREW NOTICED THAT THE RUDDER PEDALS WERE NO LONGER SYMMETRICAL COMPARED TO EACH OTHER. A MAINTENANCE TECHNICIAN INSPECTED THE CO-PILOT’S LH PEDAL (P/N-DA4-2723-35-00) AND NOTICED THAT THE VERTICAL WEB THAT CONNECTS THE PEDAL TO THE BRAKE MASTER CYLINDER ROD HAD TORN AT THE WELDED INTERSECTION OF THE TUBE THAT IT IS WELDED TO. THE TEAR/CRACK IN THE HORIZONTAL PEDAL PIVOT TUBE INDICATES A TORSIONAL FAILURE OF THAT TUBE.

NX4R20110301003

DIAMON

 

 

PEDAL

CRACKED

3/1/2011

DA42

 

 

DA427233500

ZONE 100

DURING PREFLIGHT, THE FLIGHT CREW NOTICED THAT THE RUDDER PEDALS WERE NO LONGER SYMMETRICAL COMPARED TO EACH OTHER. A MAINTENANCE TECHNICIAN INSPECTED THE LT PEDAL (P/N-DA4-2723-35-00) AND NOTICED THAT THE VERTICAL WEB THAT CONNECTS THE PEDAL TO THE BRAKE MASTER CYLINDER ROD HAD TORN AT THE WELDED INTERSECTION OF THE TUBE THAT IT IS WELDED TO. THE TEAR/CRACK IN THE HORIZONTAL PEDAL PIVOT TUBE INDICATES A TORSIONAL FAILURE OF THAT TUBE.

2011FA0000146

DIAMON

THIELT

 

CLUTCH

FAILED

3/3/2011

DA42

TAE1250299

 

057211K006002AT

RT ENGINE

CLUTCH DISC LINING FAILURE, CAUSE UNKNOWN. DAMAGE TO THE CLUTCH PRESSURE PLATE AND ENGINE FLYWHEEL OCCURED. ENGINE AUTOMATICALLY SHUTDOWN DUE TO OVERSPEED SIGNAL AS COMMANDED BY THE FADEC CONTROL. UNSCHEDULED ON AIRPORT LANDING SUCCESSFUL.

EE4Y20110134

DOUG

 

 

FRAME

CRACKED

3/1/2011

DC933F

 

 

 

ZONE 200

DURING THE INSPECTION COOOPESA FOUND AT UPPER FUSELAGE COCKPIT, STA 83.550 AT +Z42.00 AND +X 100 HORIZOLTAL FRAME CRACKED.

EE4Y20110135

DOUG

 

 

FRAME

CRACKED

3/1/2011

DC933F

 

 

 

ZONE 200

DURING THE INSPECTION COOOPESA FOUND AT UPPER FUSELAGE COCKPIT, STA 83.550 AT +Z42.00 AND -X 10 HORIZOLTAL FRAME CRACKED.

EE4Y20110137

DOUG

 

 

FITTING

CRACKED

3/7/2011

DC933F

 

 

39571742

ZONE 100

FOUND AT STA Y1077 BWTN LONG 25R AND 27R, FITTING CRACKED. DAMAGED PART WILL BE REPLACED IAW NRI 1-217.

EE4Y20110136

DOUG

 

 

FITTING

CRACKED

3/7/2011

DC933F

 

 

39216851

ZONE 100

FOUND AT MAIN CARGO DOOR LOWER JAMB, STA Y 301.5 BETWEEN LOND. 19L AND 20L, FRAME FITTING CRACKED. DAMAGED PART WILL BE REPLACED WITH NO ROUTINE ITEM 1-167.

EE4Y20110138

DOUG

 

 

VANE

BULGED

3/9/2011

DC933F

 

 

5910042503

LT WING TE FLAP

LT WING FLAP CTR FIXED VANE LOWER SKIN BULGED AT INBD AREA.

EE4Y20110131

DOUG

 

 

SKIN

CORRODED

2/28/2011

DC982

 

 

 

ZONE 100

SKIN CORRODED LOCATED FROM STA Y180 TO STA Y190 BTWN LONG 29L AND LONG 30

EE4Y20110132

DOUG

 

 

SKIN

CORRODED

2/28/2011

DC982

 

 

 

ZONE 100

SKIN CORRODED LOCATED FROM STA Y1155 TO STA Y12111 BTWN LONG 26R AND LONG 28R

EE4Y20110133

DOUG

 

 

SKIN

CORRODED

2/28/2011

DC982

 

 

 

ZONE 100

SKIN CORRODED AT STA Y725 BTWN LONG 29R AND LONG 30R.

EE4Y20110126

DOUG

 

 

LONGERON

CORRODED

2/23/2011

DC982

 

 

 

ZONE 100

LOWER FUSELAGE AFT CARGO COMPARMENT LONGERON 30 WITH CORROSION FROM STA Y 1024 TO STA Y 1032

EE4Y2011052

DOUG

 

 

SKIN

DENTED

2/17/2011

DC982

 

 

 

ZONE 100

LOWER FUSELAGE AT STA 459 BETWEEN LONG 21R AND 22R SKIN DENTED. FUSELAGE REPAIRED IAW MFG DWG SG09530001, VIEW D1, SHEETS 1 AND 3.

EE4Y20110113

DOUG

 

 

SUPPORT FITTING

CORRODED

2/17/2011

DC982

 

 

3936595528

ZONE 100

REPORTED AT AFT CARGO COMPARTMENT YSTA 1307, -X16, SUPPORT FITTING CORRODED.

EE4Y20110111

DOUG

 

 

FITTING

CORRODED

2/17/2011

DC982

 

 

5956034551

ZONE 100

REPORTED FITTING CORRODED, LOCATED AT MID C/C AT STA 769 AT +X16. THE FITTING DAMAGED WAS REPLACED.

EE4Y20110109

DOUG

 

 

LONGERON

CORRODED

2/15/2011

DC982

 

 

59360271

ZONE 100

DURING THE INSP FOUND THE LONG 30 CORRODED FROM 1147 TO 1201 IN SEVERAL PARTS.

EE4Y2011051

DOUG

 

 

FITTING

CORRODED

1/28/2011

DC982

 

 

59360541

ZONE 100

REPORTED END FITTING CORRODED LOCATED ON MID C/C STA Y820, LONG 29R.

EE4Y20110106

DOUG

 

 

FRAME

CORRODED

2/14/2011

DC982

 

 

 

BS 598

LOWER FUSELAGE MID CARGO COMPARMENT YSTA 598 BETWEEN LONGERON 27LT AND 27RT FRAME CORRODED.

EE4Y20110107

DOUG

 

 

SKIN

CORRODED

2/15/2011

DC982

 

 

 

ZONE 100

REPORTED LOWER FUSELAGE FROM YSTA 759.5 TO YSTA 826 AND BETWEEN LONG 27L AND 27R EXTERNAL SKIN WITH CORROSION AT SEVERAL PLACES.

EE4Y20110052

DOUG

 

 

FLOOR SUPPORT

CORRODED

1/28/2011

DC982

 

 

59567011

ZONE 100

FLOOR SUPPORT CORRODED LOCATED ON MID C/C STA Y598, BTW -X16 AND +X16.

EE4Y20110115

DOUG

 

 

FITTING

CORRODED

2/17/2011

DC982

 

 

3936595511

ZONE 100

REPORTED FITTING CORRODED LOCATED AT AFT CARGO COMPT AT STA 1231 BTWN LONG 27R AND LONG 28R. THE FITTING DAMAGED WAS REPLACED.

EE4Y20110110

DOUG

 

 

FLOORBEAM

CORRODED

2/17/2011

DC982

 

 

593639543

ZONE 100

REPORTED SUPPORT TEE CORRODED, LOCATED LOWER FUSELAGE FILLET FAIRING AREA AT STA Y988, BTWN +20 AND -X20. THE SUPPORT TEE DAMAGED WAS REPLACED.

EE4Y20110112

DOUG

 

 

FLOORBEAM

CORRODED

2/17/2011

DC982

 

 

5936597521

ZONE 100

REPORTED SUPPORT FITTING CORRODED LOCATED AT AFT C/C AT STA Y1174, -X2. THE PART DAMAGED WAS REPLACED.

EE4Y20110114

DOUG

 

 

FITTING

CORRODED

2/17/2011

DC982

 

 

3936595547

ZONE 100

REPORTED FITTING CORRODED LOCATED IN THE AFT CARGO COMPT AT STA 1218 BTWN LONG 27R AND LONG 28R. THE FITTING DAMAGED WAS REPLACED.

EE4Y20110117

DOUG

 

 

DOUBLER

CRACKED

2/25/2011

DC982

 

 

 

ZONE 500

DOUBLER CRACKED LOCATED LT WING UPPER SURFACE AT STA XCW110 MLG

EE4Y20110116

DOUG

 

 

SKIN

DENTED

2/25/2011

DC982

 

 

 

ZONE 100

LOWER FUSELAGE AT STA Y459 BTWN LONG 21R AND LONG 22R SKIN DENTED

EE4Y20110118

DOUG

 

 

SKIN

DENTED

2/25/2011

DC982

 

 

 

ZONE 100

LOWER FUSELAGE AT STA Y359 BTWN LONG 21R AND LONG 22R SKIN DENTED

EE4Y20110119

DOUG

 

 

SKIN

DAMAGED

2/25/2011

DC982

 

 

 

ZONE 100

LOWER FUSELAGE AT STA Y257 BTWN LONG 21R AND LONG 22R SKIN WITH BLENDOUT

EE4Y20110120

DOUG

 

 

SKIN

DENTED

2/25/2011

DC982

 

 

 

ZONE 100

LOWER FUSELAGE AT STA Y441.5 BTWN LONG 21R AND LONG 22R SKIN DENTED.

EE4Y20110127

DOUG

 

 

LONGERON

CORRODED

2/23/2011

DC982

 

 

 

ZONE 100

LOWER FUSELAGE AFT CARGO COMPARMENT LONGERON 29LH WITH CORROSIONAT STA Y 1026

EE4Y20110121

DOUG

 

 

SKIN

DENTED

2/22/2011

DC982

 

 

 

BS 1305

LOWER FUSELAGE AT Y STA 1305 BETWEEN LONGERONS 18R AND 19R SKIN WITH DENT AND SCRATCH.

EE4Y20110122

DOUG

 

 

SKIN

DENTED

2/22/2011

DC982

 

 

 

BS 359

LOWER FUSELAGE, AT Y STA 359 BETWEEN LONGERONS 21R AND 22R SKIN DENTED.

EE4Y20110123

DOUG

 

 

SKIN

BULGED

2/22/2011

DC982

 

 

 

BS 229

LOWER FUSELAGE AT STA 229 BETWEEN LONGERONS 30 AND 29L SKIN BULGED

EE4Y20110124

DOUG

 

 

SKIN

DENTED

2/22/2011

DC982

 

 

 

BS 219

LOWER FUSELAGE STA 215 BETWEEN LONGERONS 18L AND 19L SKIN DENTED.

EE4Y20110125

DOUG

 

 

SKIN

BULGED

2/22/2011

DC982

 

 

 

BS 216

LOWER FUSELAGE STA 216 BETWEEN LONGERONS 18R AND 19R SKIN BULGED.

EE4Y20110108

DOUG

PWA   

 

LONGERON

CORRODED

2/15/2011

DC982

PT6*

 

59360281

ZONE 100

DURING THE INSP, FOUND LONG 30 CORRODED FROM 1119 TO 1200. ACTION THE LONG REPAIRED TO EO.

2011FA0000165

DOUG

 

 

PA SYSTEM

INTERMITTENT

3/10/2011

DC983

 

 

 

CABIN

L-1 PA SYS-CAN NOT HEAR, INTERMITTENT FROM ALL STA SYS DEFERED AND ACFT WAS RELEASED UNDER MEL 23-6-1.

EE4Y1104001

DOUG

 

 

SUPPORT ANGLE

CRACKED

4/13/2011

MD83

 

 

5956034551

FUSELAGE

COO REPORTS LOWER FUSELAGE MID CARGO COMPARTMENT AT Y STA 788 BETWEEN LONG 27L AND 28L SUPPORT ANGLE WITH CRACK.

EE4Y1104002

DOUG

 

 

FLOOR SUPPORT

CORRODED

4/13/2011

MD83

 

 

5936597514

FUSELAGE

COO REPORTS LOWER FUSELAGE FWD CARGO COMPARTMENT AT Y STA 427, BETWEEN LONG 28L AND 29R FLOOR SUPPORT WITH CORROSION IN SEVERAL PLACES.

EE4Y1104003

DOUG

 

 

ATTACH ANGLE

CORRODED

4/13/2011

MD83

 

 

39364451

FUSELAGE

COO REPORTS LOWER FUSELAGE AFT CARGO COMPARTMENT AT Y STA 1098 AT LONGERON 30 ATTACHMENTS ANGLE WITH CORROSION.

EE4Y1104005

DOUG

 

 

RIB   

CRACKED

4/13/2011

MD83

 

 

 

LE SLAT

LT WING LEADING EDGE CAVITY NR 4 SLAT, I/B RIB CRACKED AT XRS 100. ACTION CORRECTIVE, FAA DER REPAIR APPROVAL.

EE4Y1104006

DOUG

 

 

SKIN

DENTED

4/13/2011

MD83

 

 

 

FUSELAGE

UPPER FUSELAGE FROM Y STA 200 T Y STA 217 BETWEEN LONG 13 AND 16 LT SKIN WITH DENTS IN SEVERAL PLACES. ACTION CORRECTIVE FAA DER REPAIR APPROVAL.

EE4Y1104007

DOUG

 

 

FLOOR SUPPORT

DAMAGED

4/13/2011

MD83

 

 

 

FUSELAGE

LOWER FUSELAGE, FWD CARGO COMPARTMENT FROM Y STA 370 T Y STA 427 AT LONG 29R FLOOR SUPPORT WITH ELONGATED HOLES. REPLACED PART DAMAGE.

EE4Y1104008

DOUG

 

 

PLATE

CRACKED

4/13/2011

MD83

 

 

 

RT WING

RT WING T/E AT XCW 47.45 DEBRIS DEFLECTOR PLATE CRACKED. REPLACE THE PART.

EE4Y1104009

DOUG

 

 

FITTING

CORRODED

4/13/2011

MD83

 

 

99360737

FUSELAGE

LOWER FUSELAGE AFT CARGO COMPARTMENT AT STA 1155 BETWEEN LONG 29R AND 30 CLIP CORRODED.

EE4Y1104010

DOUG

 

 

LONGERON

CORRODED

4/13/2011

MD83

 

 

5936431501

FUSELAGE

LOWER FUSELAGE AFT CARGO COMPARTMENT AT STA 1201.5, LONG 28L CORRODED.

EE4Y1104011

DOUG

 

 

SKIN

DENTED

4/18/2011

MD83

 

 

 

FUSELAGE

LOWER FUSELAGE EXTERNAL FUSELAGE AT STA 250.5 BETWEEN LONGERONS 18L AND 19L SKIN DENTED. REPAIRED WITH A FAA DER.

EE4Y1104012

DOUG

 

 

SKIN

DENTED

4/18/2011

MD83

 

 

 

FUSELAGE

LOWER FUSELAGE AT 226.5 AND 258.5 BETWEEN LONG 19 LT AND 19 LT SKIN WITH DENTS.

EE4Y1104013

DOUG

 

 

SKIN

DENTED

4/18/2011

MD83

 

 

 

FUSELAGE

UPPER FUSELAGE, AT 1187 AND 1174 BTWEEN LONG 17 LT AND 18 LT, SKIN WITH DENTS. REPAIRED WITH A FAA DER APPROVAL.

EE4Y1104014

DOUG

 

 

SKIN

DENTED

4/18/2011

MD83

 

 

 

FUSELAGE

LOWER FUSELAGE AT Y STA 383.5 BETWEEN LONG 19R AND 20R SKIN WITH A DENT.

EE4Y1104015

DOUG

 

 

SKIN

DENTED

4/18/2011

MD83

 

 

 

FUSELAGE

LOWER FUSELAGE FROM YSTA 1330 TO 1338 BETWEEN LONGERON 20LT AND 21 LT SKIN DENTED.

EE4Y1104016

DOUG

 

 

SUPPORT

CRACKED

4/18/2011

MD83

 

 

39379391

FUSELAGE

LOWER FUSELAGE FWD CARGO COMPARTMENT AT STA 465,-X30 CAB FLOORBEAM AREA WATER HOSE SUPPORT CRACKED.

2011FA0000133

EMB   

 

EMB   

AXLE

SHEARED

2/15/2011

EMB145

 

 

23092029001

MLG  

DURING DISASSEMBLY OF THE LANDING GEAR AT O/H. WHILE ACCOMPLISHING THE UNTORQUE CHECK IAW SP 145-32-0097, THE NUT FELL OFF THE SUBJECT AXLE AS TORQUE WAS APPLIED TO THE UPPER ATTACH AXLE. THE AXLE HAD SHEARED AT THE POINT WHERE THE THREADS ENTERED THE NUT. THE OPERATOR WAS INFORMED OF THE DEFECT BY PHONE AND EMAIL . THE SUBJECT AXLE WAS ALSO DELIVERED TO THE OPERATOR.

V0XR201102230001

EMB   

 

 

SEAT TRACK

CORRODED

2/23/2011

EMB145EP

 

 

14530659011

ZONE 100

SEAT TRACK B ROW NR 1 SEAT AT FR 19-24 CORRODED BEYOND LIMITS. REMOVED AND REPLACED SEAT TRACK. W/C 2129

V0XR201102230002A

EMB   

 

 

SEAT TRACK

CORRODED

2/23/2011

EMB145EP

 

 

14532605009

ZONE 100

SEAT TRACK A ROW NR 6 SEAT AT FR 53-59 CORRODED BEYOND LIMITS. REMOVED AND REPLACED SEAT TRACK. W/C 2134

V0XR201103090006

EMB   

 

 

SILL

CRACKED

3/9/2011

EMB145EP

 

 

14525800010

ZONE 100

RT SILL AT FR 36-41 IS CORRODED BEYOND LIMITS. R & R SILL.

V0XR201103090001

EMB   

 

 

ATTACH ANGLE

CRACKED

3/9/2011

EMB145EP

 

 

14542773004

ZONE 100

RT OTBD REAR RIB ATTACHMENT ANGLE CRACKED. R & R RIB.

V0XR201103090005

EMB   

 

 

SILL

CRACKED

3/9/2011

EMB145EP

 

 

14529495005

ZONE 100

RT SILL AT FR 53-59 IS CORRODED BEYOND LIMITS. R & R SILL.

V0XR201103090009

EMB   

 

 

PARTITION

CRACKED

3/9/2011

EMB145EP

 

 

14525991003

ZONE 100

LT PARTITIAN AT FR 61 IS CORRODED BEYOND LIMITS. R & R PARTITIAN.

V0XR201103080014A

EMB   

 

 

GUSSET

CORRODED

3/8/2011

EMB145EP

 

 

14530634011

ZONE 100

CENTER GUSSET AT FR 47-52 IS CORRODED BEYOND LIMITS. R & R GUSSET.

V0XR201103080014

EMB   

 

 

SILL

CORRODED

3/8/2011

EMB145EP

 

 

14525800016

ZONE 100

RT SILL AT FR 48-52 IS CORRODED BEYOND LIMITS. R & R SILL.

V0XR201103080015

EMB   

 

 

STRIP

CORRODED

3/8/2011

EMB145EP

 

 

14572021002

ZONE 100

UPPER FAIRING STRIP ON RT SIDE STA 12473.0-13893.8 IS CRACKED. R & R STRIP.

V0XR201103090015

EMB   

 

 

SEAT TRACK

CRACKED

3/9/2011

EMB145EP

 

 

14532606015

ZONE 100

SEAT TRACK RT POSITION D STA 12176.2-15506.5 IS CORRODED BEYOND LIMITS. R & R SEAT TRACK.

V0XR201103090016

EMB   

 

 

SEAT TRACK

CRACKED

3/9/2011

EMB145EP

 

 

14532606017

ZONE 100

SEAT TRACK LT POSITION A STA 15506.5-17913.2 IS CORRODED BEYOND LIMITS. R & R SEAT TRACK.

V0XR201103090017

EMB   

 

 

SEAT TRACK

CRACKED

3/9/2011

EMB145EP

 

 

14532606011

ZONE 100

SEAT TRACK LT POSITION A STA 4154.5-7131.0 IS CORRODED BEYOND LIMITS. R & R SEAT TRACK.

V0XR201103090018

EMB   

 

 

RIB   

CRACKED

3/9/2011

EMB145EP

 

 

14576631621

NR 1 NACELLE

NR 1 ENGINE BOTTOM COWL, AFT RIB IS CRACKED BEYOND LIMITS. R & R RIB.

V0XR201103090003

EMB   

 

 

SILL

CRACKED

3/9/2011

EMB145EP

 

 

14520609001

ZONE 100

LEFT FLOOR SILL AT FR 24-29 IS CORRODED BEYOND LIMITS. R & R SILL.

V0XR201103090014

EMB   

 

 

SEAT TRACK

CRACKED

3/9/2011

EMB145EP

 

 

14532606015

ZONE 100

SEAT TRACK LT POSITION D STA 12176.2-15506.5 IS CORRODED BEYOND LIMITS. R & R SEAT TRACK.

V0XR201103090004

EMB   

 

 

BEAM

CRACKED

3/9/2011

EMB145EP

 

 

14530635001

ZONE 100

LT BEAM AT FR 53-59 LY 479.0 IS CORRODED BEYOND LIMITS. R & R BEAM.

V0XR201103090007

EMB   

 

 

SILL

CRACKED

3/9/2011

EMB145EP

 

 

14525800014

ZONE 100

RT SILL AT FR 41-48 IS CORRODED BEYOND LIMITS. R & R SILL.

V0XR201103090010

EMB   

 

 

SEAT TRACK

CRACKED

3/9/2011

EMB145EP

 

 

14532606001

ZONE 100

SEAT TRACK LT POSITION A STA 7324.0-9814.0 IS CORRODED BEYOND LIMITS. R & R SEAT TRACK.

V0XR201103090011

EMB   

 

 

SEAT TRACK

CRACKED

3/9/2011

EMB145EP

 

 

14532605001

ZONE 100

SEAT TRACK RT POSITION D STA 7324.0-9814.0 IS CORRODED BEYOND LIMITS. R & R SEAT TRACK.

V0XR201103090012

EMB   

 

 

SEAT TRACK

CRACKED

3/9/2011

EMB145EP

 

 

14532606003

ZONE 100

SEAT TRACK LT POSITION D STA 9814.0-12176.2 IS CORRODED BEYOND LIMITS. R & R SEAT TRACK.

V0XR201103090013

EMB   

 

 

SEAT TRACK

CRACKED

3/9/2011

EMB145EP

 

 

14532605003

ZONE 100

SEAT TRACK RT POSITION D STA 9814.0-12176.2 IS CORRODED BEYOND LIMITS. R & R SEAT TRACK.

V0XR201103110013

EMB   

 

 

GUSSET

CRACKED

3/11/2011

EMB145EP

 

 

14530633006

ZONE 100

CTR GUSSET AT FR 29-36 IS CORRODED BEYOND LIMITS. R & R GUSSET.

V0XR201103110014

EMB   

 

 

SUPPORT

CORRODED

3/11/2011

EMB145EP

 

 

7475T761

ZONE 100

CENTER BEAM SUPPORT AT FR 60 IS CORRODED BEYOND LIMITS. R & R CTR BEAM SUPPORT.

V0XR201103110017

EMB   

 

 

SEAT TRACK

CORRODED

3/11/2011

EMB145EP

 

 

14530659007

ZONE 100

LEFT SEAT TRACK POSITION B STA 15506.5-17913.2 IS CORRODED BEYOND LIMITS. R & R SEAT TRACK.

V0XR201103110015

EMB   

 

 

SEAT TRACK

CORRODED

3/11/2011

EMB145EP

 

 

14530658001

ZONE 100

RT SEAT TRACK POSITION C STA 7324.0 - STA 9814.0 IS CORRODED BEYOND LIMITS. R & R SEAT TRACK.

V0XR201103110016

EMB   

 

 

SEAT TRACK

CORRODED

3/11/2011

EMB145EP

 

 

14530658003

ZONE 100

RT SEAT TRACK POSITION C STA 9814.0-1276.2 IS CORRODED BEYOND LIMITS. R & R SEAT TRACK.

V0XR201103110018

EMB   

 

 

SEAT TRACK

CORRODED

3/11/2011

EMB145EP

 

 

14530658007

ZONE 100

RT SEAT TRACK POSITION C STA 15506.5-17913.2 IS CORRODED BEYOND LIMITS. R & R SEAT TRACK.

V0XR201103110019

EMB   

 

 

SEAT TRACK

CORRODED

3/11/2011

EMB145EP

 

 

14532606009

ZONE 100

LT SEAT TRACK POSITION A STA 17913.2-20230.0 IS CORRODED BEYOND LIMITS. R & R SEAT TRACK.

V0XR201103110001

EMB   

 

 

COVER

CRACKED

3/11/2011

EMB145EP

 

 

14532310401

ZONE 100

COVER ASSY ON AFT LT FORNER OF WING BOX CRACKED. R & R COVER ASSY.

V0XR201103110002

EMB   

 

 

SILL

CORRODED

3/11/2011

EMB145EP

 

 

14525422001

ZONE 100

LEFT SILL AT 61-65 IS CORRODED BEYOND LIMITS. R & R SILL.

V0XR201103110020

EMB   

 

 

SEAT TRACK

CORRODED

3/11/2011

EMB145EP

 

 

14530658009

ZONE 100

RT SEAT TRACK POSITION C STA 17913.2-20230.0 IS CORRODED BEYOND LIMITS. R & R SEAT TRACK.

V0XR201103110021

EMB   

 

 

FAIRING

CORRODED

3/11/2011

EMB145EP

 

 

14530764401

ZONE 200

COCKPIT CTR WINDSHIELD UPPER FAIRING IS DAMAGED. R & R FAIRING.

V0XR201103110003

EMB   

 

 

SILL

CORRODED

3/11/2011

EMB145EP

 

 

14529495003

ZONE 100

LT SILL AT 59-61 IS CORRODED BEYOND LIMITS. R & R SILL.

V0XR201103110005

EMB   

 

 

GUSSET

CORRODED

3/11/2011

EMB145EP

 

 

14540484403

ZONE 100

CTR GUSSET AT 59-61 IS CORRODED BEYOND LIMITS. R & R GUSSET.

V0XR201103110008

EMB   

 

 

BEAM

CORRODED

3/11/2011

EMB145EP

 

 

14522215407

ZONE 100

CTR BEAM AT Y0.0 FR 58-63 IS CORRODED BEYOND LIMITS. R & R BEAM.

V0XR201103110009

EMB   

 

 

SHEAR TIE

CORRODED

3/11/2011

EMB145EP

 

 

14522464001

ZONE 100

FRAME FOOT AT FR 60 STA 17R-18R IS CORRODED BEYOND LIMITS. R & R SHEAR CLIP.

V0XR201103110010

EMB   

 

 

FITTING

BROKEN

3/11/2011

EMB145EP

 

 

14534469001

ZONE 100

STANDOFF AT FR 20 BROKEN. R & R STANDOFF.

V0XR201103110011

EMB   

 

 

STAND OFF

BROKEN

3/11/2011

EMB145EP

 

 

14534914001

ZONE 100

STANDOFF AT FR 25 BROKEN. R & R STANDOFF.

V0XR201103110012

EMB   

 

 

DUCT

CRACKED

3/11/2011

EMB145EP

 

 

14526834407

ZONE 100

GASPER DUCT ASSY IS CRACKED UNDER FLOOR BETWEEN FR 47-48. R & R DUCT ASSY.

V0XR201103110006

EMB   

 

 

GUSSET

CORRODED

3/11/2011

EMB145EP

 

 

14521699003

ZONE 100

LEFT GUSSET AT 19-23 IS CORRODED BEYOND LIMITS. R & R GUSSET.

V0XR201103110007

EMB   

 

 

PROFILE

CORRODED

3/11/2011

EMB145EP

 

 

14525994003

ZONE 100

RT PROFILE AT 61 IS CORRODED BEYOND LIMITS. R & R PROFILE.

V0XR20110311005

EMB   

 

 

GUSSET

CORRODED

3/11/2011

EMB145EP

 

 

14522215419

ZONE 100

RT GUSSET AT FR 59-61 IS CORRODED BEYOND LIMITS. R & R GUSSET.

V0XR201103030001

EMB   

 

 

SILL

CORRODED

3/3/2011

EMB145EP

 

 

14525518004

ZONE 100

RT SILL ANGLE AT FR 65 IS CORRODED BEYOND LIMITS. R & R SILL.

V0XR201103030003

EMB   

 

 

SUPPORT

CORRODED

3/3/2011

EMB145EP

 

 

14522459003

ZONE 100

RAMP UP ANGLE AT FR 18-20 IS CORRODED BEYOND LIMITS. REMOVED AND REPLACED SUPPORT.

V0XR201103030004

EMB   

 

 

SUPPORT

CORRODED

3/3/2011

EMB145EP

 

 

14521725013

ZONE 100

SERVICE DOOR FWD SILL IS CORRODED BEYOND LIMITS. REMOVED AND REPLACED SILL.

V0XR201103030005

EMB   

 

 

SILL

CORRODED

3/3/2011

EMB145EP

 

 

14521725015

ZONE 100

SERVICE DOOR AFT SILL AT FR 22-23 IS CORRODED BEYOND LIMITS. REMOVED AND REPLACED SILL.

V0XR201103030006

EMB   

 

 

GUSSET

CORRODED

3/3/2011

EMB145EP

 

 

14530633003

ZONE 100

RIGHT SIDE FLOOR GUSSET AT FR 24-29 IS CORRODED BEYOND LIMITS. REMOVED AND REPLACED FLOOR GUSSET.

V0XR201103030007A

EMB   

 

 

FLOOR SUPPORT

CORRODED

3/3/2011

EMB145EP

 

 

14520609007

ZONE 100

RT FLOOR SUPPORT AT FR 29-35 IS CORRODED BEYOND LIMITS. REMOVED AND REPLACED FLOOR SUPPORT.

V0XR201103030008

EMB   

 

 

FLOOR SUPPORT

CORRODED

3/3/2011

EMB145EP

 

 

14520609003

ZONE 100

LT FLOOR SUPPORT AT FR 29-35 IS CORRODED BEYOND LIMITS. REMOVED AND REPLACED FLOOR SUPPORT.

V0XR201103030009

EMB   

 

 

FLOOR SUPPORT

CORRODED

3/3/2011

EMB145EP

 

 

14521713005

ZONE 100

CENTER OMEGA BEAM YO.O AT FR 24-18 IS CORRODED BEYOND LIMITS. REMOVED AND REPLACED BEAM.

V0XR201103030010

EMB   

 

 

FLOOR SUPPORT

CORRODED

3/3/2011

EMB145EP

 

 

14521725001

ZONE 100

LEFT FLOOR SUPPORT AT FR 18-23 IS CORRODED BEYOND LIMITS. REMOVED AND REPLACED FLOOR SUPPORT.

V0XR201103030011

EMB   

 

 

SUPPORT

CRACKED

3/3/2011

EMB145EP

 

 

14590082003

ZONE 100

BEAM SUPPORT ANGLE AT FR 20 YO.O IS CRACKED. REMOVED AND REPLACED ANGLE.

V0XR201103030012

EMB   

 

 

ANGLE

CORRODED

3/3/2011

EMB145EP

 

 

14529150009

ZONE 100

ANGLE AT FR 24 IS CORRODED. REMOVED AND REPLACED ANGLE.

V0XR201103030013

EMB   

 

 

ANGLE

CORRODED

3/3/2011

EMB145EP

 

 

14529063007

ZONE 100

ANGLE AT FR 24 IS CORRODED. REMOVED AND REPLACED ANGLE.

V0XR201103030014

EMB   

 

 

PARTITION

CORRODED

3/3/2011

EMB145EP

 

 

14525991004

ZONE 100

RT PARTITIAN AT FR 61 IS CORRODED. REMOVED AND REPLACED PARTITIAN.

V0XR201103070002

EMB   

 

 

SILL

CORRODED

3/7/2011

EMB145EP

 

 

14522178605

ZONE 100

SERVICE DOOR SILL AT FR 20-22 IS CORRODED BEYOND LIMITS. R & R SILL.

V0XR201103070003

EMB   

 

 

ANGLE

CORRODED

3/7/2011

EMB145EP

 

 

14521718007

ZONE 100

LOWER AFT FLOOR RAMP ANGLE AT FR 19 IS CORRODED BEYOND LIMITS. RT PROFILE.

V0XR201103070004

EMB   

 

 

PROFILE

CORRODED

3/7/2011

EMB145EP

 

 

14525140023

ZONE 100

INSIDE PAX DOOR PROFILE AT FR 17-18 IS CORRODED BEYOND LIMITS. R & R PROFILE.

V0XR201103070001

EMB   

 

 

PROFILE

CORRODED

3/7/2011

EMB145EP

 

 

14522463003

ZONE 100

PROFILE AT FR 22 Y 479.0 TO OTBD IS CORRODED BEYOND LIMITS. R & R PROFILE.

V0XR201103040001

EMB   

 

 

SILL

CORRODED

3/4/2011

EMB145EP

 

 

14525422003

ZONE 100

RT SILL AT FR 61-65 IS CORRODED BEYOND LIMITS. R & R SILL.

V0XR201103040003

EMB   

 

 

GUSSET

CORRODED

3/4/2011

EMB145EP

 

 

14522460013

ZONE 100

GUSSET ON CENTER BEAM AT FR 23-19, Y00 IS CORRODED BEYOND LIMITS. R & R GUSSET.

V0XR201103040004

EMB   

 

 

PLATE

CORRODED

3/4/2011

EMB145EP

 

 

14521721009

ZONE 100

FWD DIGITAL PLATE AT FR 17-14 IS CORRODED BEYOND LIMITS. R & R DIGITAL PLATE.

V0XR201103040008

EMB   

 

 

STRIP

CRACKED

3/4/2011

EMB145EP

 

 

14572167003

ZONE 100

LEFT AFT UPPER FAIRING STIP BETWEEN STA 16143.5 - 17445.0 CRACKED. R & R STRIP.

V0XR201103040005

EMB   

 

 

GUSSET

CORRODED

3/4/2011

EMB145EP

 

 

14522460015

ZONE 100

HORSESHOE DIGITAL PLATE AT FR 17-18 IS CORRODED BEYOND LIMITS. R & R GUSSET.

V0XR201103040010

EMB   

 

 

SEAT TRACK

WORN

3/4/2011

EMB145EP

 

 

14533668601

ZONE 100

LT AND RT PILOT AND CO-PILOT SEAT TRACKS WORN BEYOND LIMITS. R & R SEAT TRACKS.

V0XR201103040007

EMB   

 

 

STRIP

CRACKED

3/4/2011

EMB145EP

 

 

14572167001

ZONE 100

LT UPPER FAIRING STIP FROM STA 16143.5 IS CRACKED. R & R STRIP.

V0XR201103040006

EMB   

 

 

SILL

CORRODED

3/4/2011

EMB145EP

 

 

14529495004

ZONE 100

RT SILL AT FR 59-61 IS CORRODED BEYOND LIMITS. R & R SILL.

V0XR201103040002

EMB   

 

 

FLOOR SUPPORT

CORRODED

3/4/2011

EMB145EP

 

 

14524188003

ZONE 100

FLOOR SUPPORT AT FR 622 Y.0.0 TO Y 479.0 IS CORRODED BEYOND LIMITS. R & R PROFILE.

V0XR201103080011

EMB   

 

 

GUSSET

CORRODED

3/8/2011

EMB145EP

 

 

14530634005

ZONE 100

LEFT GUSSET AT FR 40-47 IS CORRODED BEYOND LIMITS. R & R GUSSET.

V0XR201103080012

EMB   

 

 

GUSSET

CORRODED

3/8/2011

EMB145EP

 

 

14530634009

ZONE 100

LT GUSSET AT FR 47-52 IS CORRODED BEYOND LIMITS. R & R GUSSET.

V0XR201103080013

EMB   

 

 

GUSSET

CORRODED

3/8/2011

EMB145EP

 

 

14530634003

ZONE 100

CTR GUSSET AT FR 36-40 IS CORRODED BEYOND LIMITS. R & R GUSSET.

V0XR201103080016

EMB   

 

 

LINE

CHAFED

3/8/2011

EMB145EP

 

 

14523355403

ZONE 500

LT ENGINE FIRE EXT LINE IN CARGO BAY CHAFED AND DENTED. R & R LINE.

V0XR201103080008

EMB   

 

 

SILL

CORRODED

3/8/2011

EMB145EP

 

 

14525800013

ZONE 100

LT SILL AT FR 42-49 IS CORRODED BEYOND LIMITS. R & R SILL.

V0XR201103080009

EMB   

 

 

SILL

CORRODED

3/8/2011

EMB145EP

 

 

14525800012

ZONE 100

LT SILL AT FR 49-52 IS CORRODED BEYOND LIMITS. R & R SILL.

V0XR201103080018

EMB   

 

 

LINE

DAMAGED

3/8/2011

EMB145EP

 

 

14521245413

ZONE 600

RT ENGINE FIRE BOTTLE LINE IS DAMAGED. R & R LINE.

V0XR201103080010

EMB   

 

 

GUSSET

CORRODED

3/8/2011

EMB145EP

 

 

14530634001

ZONE 100

LT GUSSET AT FR 36-40 IS CORRODED BEYOND LIMITS. R & R GUSSET.

V0XR201103070005

EMB   

 

 

GUSSET

CORRODED

3/7/2011

EMB145EP

 

 

14530634007

ZONE 100

CENTER GUSSET AT FR 40-47 IS CORRODED BEYOND LIMITS. R & R GUSSET.

V0XR201103070006

EMB   

 

 

ANGLE

CRACKED

3/7/2011

EMB145EP

 

 

14567291001

ZONE 100

LT LOWER NR 2 ATTACHMENT FAIRING BRACKET IS CRACKED. R & R ANGLE.

V0XR201103080002

EMB   

 

 

GUSSET

CORRODED

3/8/2011

EMB145EP

 

 

14530633005

ZONE 100

LEFT FLOOR GUSSET AT FR 24-29 IS CORRODED BEYOND LIMITS. R & R GUSSET.

V0XR201103080003

EMB   

 

 

SILL

CORRODED

3/8/2011

EMB145EP

 

 

14529495001

ZONE 100

LEFT SILL AT FR 53-59 LY 780.0 IS CORRODED BEYOND LIMITS. R & R SILL.

V0XR201103080004

EMB   

 

 

GUSSET

CORRODED

3/8/2011

EMB145EP

 

 

14530635003

ZONE 100

GUSSET ON CENTER OMEGA BEAM AT FR 53-59 IS CORRODED BEYOND LIMITS. R & R GUSSET.

V0XR201103080005

EMB   

 

 

GUSSET

CORRODED

3/8/2011

EMB145EP

 

 

14530633005

ZONE 100

LEFT GUSSET AT FR 29-35 IS CORRODED BEYOND LIMITS. R & R GUSSET.

V0XR20110404019A

EMB   

 

 

SEAT TRACK

CORRODED

4/4/2011

EMB145LR

 

 

14532605003

ZONE 200

PASSENGER SEAT TRACK POSITION 'D' AT STA 9814.0 - 12176.2 CORRODED UNDER SCREW HEADS. REMOVED AND REPLACED SEAT TRACK 'D' AT STA 9814.0 TO 12176.2 IAW EMB145 AMM 53-01-06. W/C 2144

V0XR201104060003

EMB   

 

 

DUCT

DAMAGED

4/6/2011

EMB145LR

 

 

14520409405

CABIN AIR

AIR CONDITIONING DUCT AT FR 15 DAMAGED. REMOVED AND REPLACED DUCT. W/C 1115

V0XR201104060012

EMB   

 

 

SEAT TRACK

CORRODED

4/6/2011

EMB145LR

 

 

14530638003

ZONE 100

PAX SEAT TRACK POSITION C AT STA. 9814.0 - 12176.2 IS CORRODED UNDER SCREW HEADS. REMOVED AND REPLACED SEAT TRACK. W/C 2139

V0XR20110329001

EMB   

 

 

STRUCTURE

CORRODED

3/29/2011

EMB145LR

 

 

14522460015

ZONE 100

(V0XR) HORSESHOE DIGITAL PLATE AT FRAME 16-18 HAS CORROSION. REMOVED AND REPLACED HORSESHOE AT FRAME 16-18 IAW EMB145 SRM 51-20-03, AND 51-40-02. W/C 1063

2011FA0000148

GROB

LYC   

 

PUMP

LEAKING

3/3/2011

G120A

AEIO540D4D5

 

RG9570K1M

ENGINE FUEL

MECHANIC PERFORMED A LEAK CHECK AFTER INSTALLING ENGINE DRIVEN FUEL PUMP ON THE ENGINE AND FOUND FUEL LEAKING FROM SHAFT DRIVE. NO PROBABLE CAUSE OR RECOMMENDATIONS AT THIS TIME.

2011FA0000149

GROB

LYC   

 

PUMP

FAILED

3/3/2011

G120A

AEIO540D4D5

 

RG9570K1M

ENGINE FUEL

AFTER INSTALLING ENGINE DRIVEN FUEL PUMP ON THE ENG, MECHANIC WENT OUT TO PERFORM AN ENGINE OPS CHECK AND FOUND ENGINE WOULDN’T KEEP RUNNING UNLESS BOOST PUMP WAS IN THE ON POSITION. UPON TROUBLESHOOTING MECHANIC FOUND THE SHAFT WAS SHEARED ON THE FUEL PUMP. NO PROBABLE CAUSE OR RECOMMENDATIONS AT THIS TIME.

2011FA0000144

GROB

LYC   

 

PUMP

LEAKING

3/2/2011

G120A

AEIO540D4D5

 

RG9570K1M

ENGINE FUEL

MECHANIC WAS PERFORMING A POST MAINTENANCE CHECK ON AIRCRAFT AND NOTICED FUEL STAINS ON THE DOG HOUSE, MECHANIC THEN PERFORMED A LEAK CHECK AND FOUND FUEL LEAKING FROM VENT ON ADJUSTMENT COVER ON ENGINE DRIVEN FUEL PUMP. NO PROBABLE CAUSE OR RECOMMENDATIONS AT THIS TIME.

CA101021011

GROB

LYC   

 

WASHER

MISSING

10/20/2010

G120A

AEIO540D4D5

 

LN9025162ST60

WING TO BODY

DURING A 200 HR INSP ON 2 OTHER ACFT, MSB 1121-109/1 WAS BEING CARRIED OUT AS REQUIRED WHEN IT WAS NOTED THAT THE WASHERS WERE MISSING. THE MFG WAS CONTACTED AND DETERMINED THAT THIS WAS A NON CONFORMANCE TO THE TYPE CERTIFICATE. IT WAS DECIDED THAT THE REMAINDER OF THE FLEET, (11 AIRCRAFT) BE INSPECTED TO DETERMINE THE STATUS OF THE ASSY. THE ENTIRE FLEET WAS INSPECTED AND ALL ACFT WERE FOUND TO BE IN NON-COMPLIANCE AND SUBSEQUENTLY GROUNDED UNTIL THE PARTS ARE INSTALLED.

CA101021012

GROB

LYC   

 

WASHER

MISSING

10/20/2010

G120A

AEIO540D4D5

 

LN9025162ST60

WING TO BODY

DURING A 200 HR INSP ON 2 OTHER ACFT, MSB 1121-109/1 WAS BEING CARRIED OUT AS REQUIRED WHEN IT WAS NOTED THAT THE WASHERS WERE MISSING. THE MFG WAS CONTACTED AND DETERMINED THAT THIS WAS NON CONFORMANCE TO THE TYPE CERTIFICATE. IT WAS DECIDED THAT THE REMAINDER OF THE FLEET, (11 ACFT) BE INSPECTED TO DETERMINE THE STATUS OF THE ASSY. THE ENTIRE FLEET WAS INSPECTED AND ALL ACFT WERE FOUND TO BE IN NON-COMPLIANCE AND SUBSEQUENTLY GROUNDED UNTIL THE PARTS ARE INSTALLED.

CA101021013

GROB

LYC   

 

WASHER

MISSING

10/19/2010

G120A

AEIO540D4D5

 

LN9025162ST60

WING TO BODY

DURING A 200 HR INSP ON ACFT, MSB 1121-109/1 WAS BEING CARRIED OUT AS REQUIRED WHEN IT WAS NOTED THAT THE WASHERS WERE MISSING. THE MFG WAS CONTACTED AND DETERMINED THAT THIS WAS A NON CONFORMANCE TO THE TYPE CERTIFICATE. IT WAS DECIDED THAT THE REMAINDER OF THE FLEET, (11 AFT) BE INSPECTED TO DETERMINE THE STATUS OF THE ASSY. THE ENTIRE FLEET WAS INSPECTED AND ALL ACFT WERE FOUND TO BE IN NON-COMPLIANCE AND SUBSEQUENTLY GROUNDED UNTIL THE PARTS ARE INSTALLED.

CA101021014

GROB

LYC   

 

WASHER

MISSING

10/19/2010

G120A

AEIO540D4D5

 

LN9025162ST60

 

DURING A 100 HR INSP ON ACFT, MSB 1121-109/1 WAS BEING CARRIED OUT AS REQUIRED WHEN IT WAS NOTED THAT THE WASHERS WERE MISSING. THE MFG WAS CONTACTED AND DETERMINED THAT THIS WAS A NON-CONFORMANCE TO THE TYPE CERTIFICATE. IT WAS DECIDED THAT THE REMAINDER OF THE FLEET, (11 ACFT) BE INSPECTED TO DETERMINE THE STATUS OF THE ASSY. THE ENTIRE FLEET WAS INSPECTED AND ALL ACFT WERE FOUND TO BE IN NON-COMPLIANCE AND SUBSEQUENTLY GROUNDED UNTIL THE PARTS ARE INSTALLED.

2011FA0000218

GULSTM

GARRTT

 

SHUTOFF VALVE

FAILED

3/23/2011

G150

TFE7314R

 

P23791

HYD RESERVOIR

ACFT DEPARTED AT APPROX 1630 ZULU WITH AN INTENDED DESTINATION. WHILE AT CRUISE ALTITUDE RECEIVED AN EICAS MESSAGE INDICATING THE LOSS OF RT HYD PRESSURE. ACFT ELECTED TO DIVERT, AND DURING DESCENT AT ABOUT 30 MINUTES FROM DESTINATION AN ADDITIONAL EICAS MESSAGE INDICATING A LT HYD PUMP FAILURE AND PRESSURE GAUGE READOUT OF ZERO MAIN HYD PRESSURE. AIRCREW CONDUCTED THE APPROPRIATE EMERGENCY CHECKLIST AND DECLARED AN EMERGENCY. APPROX 5 TO 7 MINUTES FROM LANDING, RECEIVED A MESSAGE INDICATING THE LOSS OF AUXILIARY HYD PRESSURE. AIRCREW CONDUCTED EMERGENCY CKLIST AND UPDATED ATC OF THEIR CONDITION. ACFT LANDED WITHOUT INCIDENT. ACFT WAS TOWED TO MFG FOR REPAIR. THEY CHANGED THE RT HYD MAIN RESERVOIR SHUT-OFF VALVE, RT ENGINE DRIVE HYD PUMP, LT ENG DRIVEN HYD PUMP AND AUX HYD PUMP. THE SUSPECTED CAUSE OF HYD FAILURE WAS DETERMINED TO BE THE FAILURE OF THE RT MN HYD SHUT-OFF VALVE NOT OPENING ENOUGH WHICH CAUSED THE HYD PUMPS TO BE STARVED OF HYD FLUID.

2011FA0000124

GULSTM

 

 

LIFE RAFT

MISMANUFACTURED

2/23/2011

GV   

 

 

1218FAUL3301100

 

AFTER INFLATION DURING A ROUTINE INSPECTION OF LIFE RAFT, OBSERVED THE LOWER BOUYANCY TUBE IS CONSIDERABLY SMALLER IN DIAMETER & CIRCUMFERENCE WHEN COMPARED TO UPPER BOUYANCY TUBE. AS A RESULT, THE LOWER TUBE SEAMS (INTERIOR OBSERVATION)ARE BOWED INWARD & FLOOR HAS EXCESSIVE CREASES. EACH OF THE LOWER TUBE CELLS ARE BOWED INWARD FROM STRESS & THE GENERAL CONDITION IS QUESTIONABLE. OUTSIDE CIRCUMFERENCE MEASUREMENTS ARE AS FOLLOWS: UPPER TUBE 28' 3", THE LOWER TUBE MEASURES 27'6". UPPER TUBE EXTENDS OUT APPROXIMATELY 2" FURTHER THAN LOWER TUBE ALL THE WAY AROUND. BOUYANCY TUBES ARE SUPPOSSED TO BE IDENTICAL. BOUYANCY TUBES ARE NOT IDENTICAL ON SUBJECT RAFT. THIS ISSUE HAS BEEN BROUGHT TO THE ATTENTION OF FSDO-11 AND PHOTOGRAPHS HAVE BEEN EMAILED TO THAT FACILITY.

2011FA0000150

HUGHES

ALLSN

 

OIL SYSTEM

WARNING LIGHT

3/2/2011

369E

250C20B

 

 

ENGINE

DURING A TOUR FLIGHT, THE PILOT GOT A ENGINE CHIP LIGHT INDICATION. THE PILOT PERFORMED AN UNEVENTFUL UNSCHEDULED LANDING. THE MX DEPARTMENT WAS DISPATCHED AND FOUND A METAL SLIVER ON THE UPPER ENGINE CHIP PLUG THAT WAS CAUSING THE LIGHT. BOTH UPPER AND LOWER PLUGS WERE INSPECTED AND CLEANED. A GROUND RUN WAS PERFORMED WITH NO CHIP LIGHT. THE PLUGS WERE INSPECTED AGAIN AND FOUND CLEAN. THE ACFT WAS RETURNED TO SERVICE.

2011FA0000163

HUGHES

ALLSN

 

ENGINE

MAKING METAL

3/8/2011

369E

250C20B

 

 

 

DURING TAKEOFF THE PILOT EXPERIENCED AN ENGINE CHIP LIGHT AND RETURNED FOR LANDING. MX FOUND SMALL CHIPS ON THE LOWER ENGINE PLUG AND A SLIVER ON THE UPPER PLUG. THE ENGINE WAS REMOVED FROM THE ACFT AND SENT TO SERVICE FOR MX.

2011FA0000108

ISRAEL  

PWC   

 

INLET SCREEN

WORN

1/16/2011

GALAXY

PW306A

 

308479501

LT ENGINE

ON RECEPTION FOR MX THE LT ENGINE INLET ACOUSTIC MESH WAS FOUND DEPARTED FROM INLET AREA AT 3PM POSITION TO 6PM POSITION. ENGINE DIGESTED THE MESH CAUSING DAMAGE TO THE INLET CASE & STATOR GUIDE VANES.

2011F00045

LEAR

 

 

FIRE LOOP

FALSE ACTIVATION

2/18/2011

35A   

 

 

 

LT NACELLE

DURING APPROACH, THE LT FIRE WARNING LIGHT ILLUMINATED AND DID NOT EXTINGUISH AFTER LANDING WHEN THE ENGINE WAS SHUTDOWN. THERE WAS NO OTHER ABNORMAL INDICATIONS. NOTE THAT THE NACELLE HEAT WAS "ON" DURING APPROACH (DUE TO CLOUDS AND RAIN). TECH WAS SENT TO THE SITE AND PERFORMED TROUBLESHOOTING. FOUND NO EVIDENCE THAT A FIRE OCCURRED. CHECKED THE FIRE LOOPS AND NO DAMAGE WAS NOTED. TESTED THE SYS AND FOUND SATISFACTORY. SQUAWK COULD NOT BE DUPLICATED. WORK PERFORMED IAW MM-99 CHAPTER 26-10-01. ACFT WAS RETURNED TO SERVICE ON 2/14/2011.

2011FA0000159

LEAR

 

 

SENSOR

FAILED

3/7/2011

35A   

 

 

12958010

DUCT TEMP

DUCT TEMP SENSOR FAILED TO ALLOW THE PRESSURIZARION SYS TO OVERTEMP THE DUCTING.

VIBR20110301

LEAR

 

 

STEERING UNIT

MISREPAIRED

3/1/2011

45LEAR

 

 

2W3201D

NLG  

NOSE LANDING GEAR STRUT WITH NOSE WHEEL STEERING GEARBOX AND ACTUATOR WERE SENT TO REPAIR STATION FOR REPAIR. RECEIVED NOSE GEAR BACK FULLY ASSEMBLED AS SHIPPED OUT. HAD DIFFICULTY GETTING NOSE GEAR STEERING TO RIG PROPERLY AND UPON FURTHER INVESTIGATION FOUND ONE OF THREE NOSE GEAR STEERING GEARBOX ATTACH BOLTS MISSING AND THE OTHER TWO OF THREE BOLTS LOOSE. THESE BOLTS ARE INTERNALLY MOUNTED IN THE GEARBOX ASSEMBLY WITH NO WAY TO INSPECT THEM WITHOUT DISASSEMBLY OF GEARBOX. NO SAFETY PROVISIONS OR TORQUE STRIPE ON BOLT HEADS OR LOCK WASHERS.

2011FA0000115

LEAR

GARRTT

 

RECEPTACLE

FAILED

2/10/2011

45LEAR

TFE731*

 

AC16707

GALLEY

THE NR1 TERMINAL AND WIRING FOR THE LIQUID WARMER POT WAS FOUND TO BE ARCED AND OVERHEATED ON THE BACK OF THE GALLEY. DURING REPLACEMENT, FOUND TERMINAL WIRING HARDWARE LOOSE.

AUCR20110215002

LKHEED

 

 

FITTING

CRACKED

2/15/2011

P3A   

 

 

9017222

BS 695

DURING ANNUAL INSP, A DETAILED ULTRA-SONIC INSP OF THE FUSELAGE WING ATTACH RING FITTINGS WERE INITIATED BY AN INTERNAL SB. A FATIGUE CRACK WAS APPRECIATED IN THE RT AFT FITTING'S VERTICAL OTBD FLANGE.

AUCR20110215003

LKHEED

 

 

ATTACH FITTING

CRACKED

2/15/2011

P3A   

 

 

9017212

BS 571

DURING ANNUAL INSPECTION, A DETAILED ULTRA-SONIC INSPECTION OF THE FUSELAGE WING ATTACH RING FITTINGS WERE INITIATED BY AN INTERNAL SB. FATIGUE CRACKS WERE APPRECIATED IN THE RT FWD FITTING'S CHORDWISE FLANGE AT THE UPPER TENSION BOLT.

AUCR20110215

LKHEED

 

 

ATTACH FITTING

CRACKED

2/15/2011

P3A   

 

 

9017211

ZONE 100

DURING ANNUAL INSPECTION, A DETAILED ULTRA-SONIC INSPECTION OF THE FUSELAGE WING ATTACH RING FITTINGS WERE INITIATED BY AN INTERNAL SB. A FATIGUE CRACK WAS APPRECIATED IN THE LT FWD FITTING, VERTICAL OTBD FLANGE APPROX 6" ABOVE UPPER TENSION BOLT.

AUCR20110215004

LKHEED

 

 

FITTING

CRACKED

2/15/2011

P3A   

 

 

9017212

ZONE 100

DURING ANNUAL INSPECTION, A DETAILED ULTRA-SONIC INSPECTION OF THE FUSELAGE WING ATTACH RING FITTINGS WERE INITIATED BY OUR BY OUR INTERNAL SB. A FATIGUE CRACK WAS APPRECIATED IN THE RT FWD FITTING JUST BELOW THE UPPER MOST AFT HOLE ON THE VERTICAL OTBD FLANGE.

AUCR20110215001

LKHEED

ALLSN

 

FLANGE

CRACKED

2/15/2011

P3A   

T56A10

 

9017212

ZONE 100

DURING ANNUAL INSPECTION A DETAILED ULTRA-SONIC INSPECTION OF THE FUSELAGE WING ATTACH RING FITTINGS WERE INITIATED BY AN INTERNAL SB. A FATIGUE CRACK WAS APPRECIATED IN THE RT FWD FITTING'S VERTICAL OTBD FLANGE.

2011FA0000102

MAULE

LYC   

 

EXHAUST PIPE

CRACKED

3/10/2010

MXT7180A

O360C4F

 

52942

RIGHT

THE RT TAILPIPE WAS SENT FOR REPAIR ON 3/10/10 BECAUSE IT WAS CRACKED.

CA101004003

MORAVN

LYC   

 

IMPULSE COUPLING

LOOSE

10/1/2010

Z242L

AEIO360A1B6

4372

M3100

MAGNETO

A LOOSE RIVET WAS FOUND ON THE IMPULSE COUPLING DURING SCHEDULED MX.

2011FA0000132

MTSBSI

GARRTT

 

SPUR GEAR

DAMAGED

2/14/2011

MU2B60

TPE331*

 

31035891

GEARBOX

FOUND TORQUE SENSOR SPUR GEAR SEVERELY DAMAGED DUE TO MATERIAL CONTACT AND OVERHEAT. GEAR HAD SEVERAL GEAR TEETH SEPARATED WITH REMAINING GEAR TEETH SHOWING SIGNIFICANT DAMAGE. THE LOWER SCAVENGE TUBE RETAINER BOLT HEAD WAS FOUND TO BE DAMAGED DUE TO CONTACT WITH THE SPUR GEAR. THE INSTALLED BOLT WAS (PN MS9556-06), THE CORRECT BOLT SHOULD HAVE BEEN A (PN MS948907 IAW MFG IPC 72-01-16, REV 9, SECTION 72-10-13, FIG 5, INDEX 185. THE (MS9556-06) BOLT HEAD HAS A HEIGHT OF .134", ALLOWED THE BOLT HEAD TO CONTACT THE SPUR GEAR AND RUB UNTIL THE GEAR EXPERIENCED MATERIAL FAILURE DUE TO OVERHEATING. ENG WAS O/H IN 2001 AND IT APPEARS THE INCORRECT BOLT WAS INSTALLED AT THAT TIME. ENGINE LOGBOOKS DO NOT SHOW ANY ACCESS TO THE REDUCTION GEARBOX SINCE ENGINE O/H WAS ACCOMPLISHED.

5APR577Y52

PILATS

PWA   

 

PRESSURE SWITCH

INTERMITTENT

3/10/2011

PC1245

PT6A67B

 

9738114306

ZONE 100

UPON LANDING GEAR RETRACTION ON CLIMB AFTER TAKEOFF, LANDING GEAR DID NOT RETRACT. THE LANDING GEAR POSITION INDICATORS REMAINED RED, AND THE HYD CAWS ILLUMINATED. THE PILOT NOTIFIED TOWER THEY WERE RETURNING TO THE FIELD THEN FOLLOWED THE APPROPRIATE CHECKLIST AND PLACED THE GEAR HANDLE IN THE DOWN POSITION. THE MLG LOCKED IN THE DOWN POSITION, THE NLG NEEDED TO BE PUMPED TO THE DOWN AND LOCKED POSITION MANUALLY. THE ACFT LANDED UNEVENTFULLY. MX TROUBLESHOT THE HYD SYS WITH NO DEFECTS NOTED. REPLACED THE HYD SYS PRESSURE SWITCH. C/W FUNCTIONAL TEST OF THE HYD SYS WITH NO DEFECTS NOTED. ALL WORK ACCOMPLISHED IAW MFG INSTRUCTIONS.

5APR577Y53

PILATS

PWA   

 

BRAKE DISC

CRACKED

3/10/2011

PC1247

PT6A67

 

244759C

ZONE 700

DURING A LINE CHECK FOUND THE LT SIDE MLG BRAKE ASSY OUTER DISK CRACKED.

CA100914004

PIPER

CONT

 

STEERING SYS

MISINSTALLED

9/14/2010

PA11

C9012F

 

750330

RUDDER ASSY

DURING INSP OF THE RUDDER ASSY. WHILE ACFT WAS DISASSEMBLED FOR O/H, IT WAS FOUND THAT DURING PREVIOUS REPLACEMENT OF ACFT FABRIC, BOLTS ATTACHING THE RUDDER STEERING ARM CASTING TO THE RUDDER ASSY HAD BEEN REMOVED TO FACILITATE THE INSTALLATION OF THE NEW FABRIC. WHEN THE NEW FABRIC WAS INSTALLED IT COVERED THE ATTACHMENT BOLT HOLES. BECAUSE THE BOLT HOLES WERE COVERED UP, THE ATTACHMENT BOLTS WERE NOT REINSTALLED. THE STEERING ARM IS AN ALUMINUM CASTING. IT FEATURES A .7500 INCH ROUND ATTACHMENT SHANK WHICH IS INSTALLED INTO THE 4130 STEEL RUDDER SPAR. CORROSION, CAUSED BY THE CONTACT OF DISSIMILAR METALS, FROZE THE PART IN PLACE. THIS RESULTED IN THE ARM NOT COMING LOOSE. ACFT APPEARS TO HAVE BEEN IN SERVICE WITHOUT THE BOLTS INSTALLED FOR APPROX 20 YEARS. AT THIS POINT, WE ARE AWAITING RECEIPT OF THE LOG BOOKS FROM OWNER TO REVIEW MX HISTORY. THE USE OF THIS PART AND THE WAY IT IS ATTACHED TO THIS ACFT IS THE SAME THROUGHOUT THE MFG SERIES ACFT THAT ARE FABRIC COVERED. IT IS STRONGLY RECOMMENDED THAT ACFT BE INSPECTED FOR THIS UNSAFE CONDITION.

2011FA0000129

PIPER

 

 

TRIM TAB

CORRODED

2/7/2011

PA23250

 

 

1561805

ELEVATOR

(PN 15618-05) ELEVATOR TRIM ARM ASSY CORRODED TO THE POINT OF HAVING A .1875 HOLE THRU BOTH SIDES OF THE TUBE ON AFT END OF TUBE.

2011FA0000217

PIPER

 

 

TIRE

DAMAGED

3/18/2011

PA28161

 

 

302246401

MLG  

TIRE DEFLATED DURING TAXIING OPERATIONS. FOUND SMALL HOLE IN SIDE WALL OF TUBE. OPPOSITE SIDE OF AND 180 DEGREE FROM VALVE STEM. SECOND OCCASION ON THIS ACFT IN 112 HRS OF OPERATION. (TIRE WAS REPLACED W/TUBE). APPEARS TO BE A MFG OR PACKAGING FLAW.

2011FA0000216

PIPER

 

 

TUBE

FLAT

3/18/2011

PA28161

 

 

302013400

MLG  

TIRE DEFLATED DURING TAXIING OPERATIONS. FOUND SMALL HOLE IN SIDE WALL OF INNER TUBE 180 DEGREE OPPOSITE VALVE STEM AND ON SIDE OF TUBE OPPOSITE OF VALVE STEM. APPEARS TO BE MFG OR PACKAGING DEFECT. (TIRE WAS REPLACED W/TUBE.) SECOND EVENT ON THIS ACFT IN 137.6 HRS. SIMILAR EVEN ON SAME TYPE ACFT.

2011FA0000168

PIPER

CONT

 

LINK

CRACKED

2/3/2011

PA28RT201T

TSIO360FB

 

76423803

NLG  

CRACK DISCOVERED IN FWD FACING RADIUS OF NOSE GEAR RETRACTION CYLINDER AND DOWN LOCK ATTACHMENT TANG DURING ANNUAL INSP. REPLACED ENTIRE NOSE GEAR LINK AND BRACE DOWN-LOCK ASSY WITH NEW TO RETURN ACFT TO AIRWORTHINESS.

KRTR200110223001

PIPER

CONT

 

ENGINE

MISOVERHAULED

1/25/2011

PA34200T

LTSIO360EB

 

LTSIO360EB1A

RIGHT

DURING REPLACEMENT OF THE STARTER ADAPTER, P/N 635048A16. NOTICED THAT THE CRANKSHAFT GEAR LOCATED AT THE AFT END OF THE CRANSHAFT DID NOT HAVE SAFETY WIRE ON THE ATTATCHMENT BOLTS. IT WAS FURTHER DISCOVERED THAT THE CAMSHAFT GEAR LOCATED AT THE AFT END OF THE CAMSHAFT ALSO DID NOT HAVE IT'S BOLTS SAFETY WIRED. THE BOLTS FOR BOTH THE CRANKSHAFT GEAR AND THE CAMSHAFT GEAR WERE TORQUE CHECKED PER THE OVERHAUL MANUAL X30596A SECTIONS 72-50-07 AND 72-50-08 AND THE TABLE OF TIGHTENING TORQUES FIGURE 72-50-01B AND WERE SECURED WITH LOCK WIRE REFERENCE THE OVERHAUL MANUAL 72-50-07 AND 72-50-08 USING THE LOCK WIRE PROCEDURE FIGURE 70-10-00. THIS ENGINE HAS A TIME SINCE OVERHAUL OF 1201.8 HOURS AND IS LOCATED AT THE RIGHT POSITION ON THE AIRCRAFT. THE LEFT ENGINE THAT WAS ALSO OVERHAULED AT THE SAME TIME AND BY THE SAME PERSON WAS INSPECTED AND WAS FOUND TO BE CORRECTLY ASSEMBLED WITH RESPECT TO THE CRANKSHAFT AND CAMSHAFT GEARS INSTALLATION.

2011FA0000127

PIPER

 

PIPER

BOLT

SHEARED

2/7/2011

PA44180

 

 

402940

DRAG LINK

AIRCRAFT EXPERIENCED A COLLAPSE OF THE NOSE GEAR DURING TAXI AFTER LANDING. AFTER RECOVERY,IT WAS DISCOVERED THAT THE DRAG LINK BOLT P/N 402-940 HAD SHEARED. I BELIEVE THE COMBINATION OF A FLAT NOSE TIRE AND UNSATISFACTORY TAXIWAY CONDITIONS(I.E. SLUSH AND ICE) AT KCMI PUT EXCESS FORCE ON THE GEAR CAUSING THE BOLT IN QUESTION TO FAIL.

2011FA0000151

PIPER

 

 

SUPPORT

CRACKED

2/24/2011

PA44180

 

 

86282010

NLG  

DURING THE SCHEDULED MAINTENANCE ON FEB 24, 2011, OUR FIELD ENGINEER FOUND THE LEFT NOSE GEAR SUPPORT(PN 86282-010) OF ONE SEMINOLE(SN 4496048)HAS A CRACK.

CA101018003

PIPER

LYC   

 

ELT   

FALSE ACTIVATION

10/15/2010

PA44180

LO360A1H6

 

4530150

CABIN

THE ELT ACTIVATED SOME TIME IN THE EVENING, POSSIBLY WHEN THE ACFT WAS PUT INTO THE HANGER. IT TURNED OFF AFTER BEING RESET. THE ELT ACTIVATED AGAIN IN THE NIGHT AND WAS NOT ABLE TO BE DEACTIVATED UNTIL THE BATTERY WAS REMOVED. THIS UNIT WAS INSTALLED APPROX 4 MONTHS PREVIOUSLY TO REPLACE AN ELT THAT HAD ACTIVATED ACCIDENTALLY. WHEN REMOVED THIS ELT, AS WELL AS THE PREVIOUS UNIT WERE BOTH FOUND TO HAVE WATER INSIDE.

CA100921003

PROPJT

PWC   

 

ENGINE

LEAKING

9/10/2010

200A

PW306A

 

 

OIL SYSTEM

SMOKE IN CABIN DURING CLIMB AT FL 50, SMOKE STARTED ENTERING THE CABIN. THE CREW ELECTED TO RETURN TO THE POINT OF DEPARTURE WHERE AN UNEVENTFUL LANDING WAS MADE. POST FLIGHT INSP FOUND OIL ON THE FAN AND THE CABIN BLEED PORT. TROUBLESHOOTING IS ON-GOING.

1013810127

RAYTHN

 

 

DE-ICE VALVE

FAILED

2/22/2011

B300RAYTHEON

 

 

10138100127

SOLENOID

MULTIPLE FAILURES OF THIS PN VALVE HAVE OCCURRED ON ACFT SINCE NEW IN JUNE OF 2005. OF THE 11 VALVES THAT HAVE BEEN REPLACED ON THIS ACFT, ALL HAVE FAILED IN THE OPEN POSITION, ALLOWING ENGINE BLEED AIR TO BE PORTED THE BRAKES AND INTO THE WHEEL WELL IF THE GEAR IS RETRACTED. THE VALVE MFG STATES THAT THIS IS CAUSED FROM SWELLING OF THE SOLENOID PISTON RINGS WHEN THE VALVE IS OPERATED IN A WET ENVIRONMENT. MOST RECENT FAILURES HAVE TSO OF 34 HRS, 65 HRS, AND 172 HRS. ALSO, FOUND ON VALVE, SN 5187, WAS IMPROPERLY CRIMPED SOLENOID POWER WIRE.

PIYR S261101160

RAYTHN

 

 

STRUT

MISALIGNED

3/15/2011

G36   

 

 

368200201

NLG  

DURING LANDING GEAR RETRACTION TEST, IT WAS NOTED THAT THE NOSE WHEEL ASSY WOULD CONTACT THE RT NOSE GEAR DOOR, AFT HINGE DURING LANDING GEAR CYCLE. IT WAS ALSO NOTED THAT THE NOSE WHEEL ASSY WOULD CONTACT THE NOSE WHEEL WELL STRUCTURE WHEN FULLY RETRACTED. PRECISION MEASUREMENTS DETERMINED THAT THE NOSE STRUT ASSY TO ACFT STRUCTURE ATTACH POINTS WERE MISALIGNED.

E81RJW304273

RAYTHN

 

 

TRANSDUCER

FAILED

2/22/2011

HAWKER800XP

 

 

3E1500A

TRIM SYNC

INVESTIGATED FLIGHT CREW REPORT OF REPEATED MACH TRIM AND ELEVATOR TRIM FAIL ANNUNCIATOR INDICATIONS DURING DESCENT. DURING TROUBLESHOOTING FOUND ELEVATOR TRIM WOULD STOP IN SAME POSITION EACH TIME DURING OPERATION. NOTED AUTOPILOT TRIM INPUTS WOULD STOP JUST BEFORE FAILURE. FOUND DUAL SYNCHRO TRANSDUCER FAILED INTERNALLY. REPLACED THE DUAL SYNCHRO TRANSDUCER WITH A SERVICEABLE UNIT, NO FAULTS NOTED DURING POST-INSTALLATION CHECKS. RECOMMEND MANUFACTURER CHECK FAILURE RATE ON THIS COMPONENT TO VERIFY AN ISOLATED CONDITION TO THIS UNIT OR A FLEET PROBLEM.

2011FA0000123

RAYTHN

 

 

CONNECTOR

BURNED

2/13/2011

HAWKER900XP

 

 

 

TERMINAL BLOCK

PREFLIGHT FOUND RT BOOST PUMP INOP. TROUBLESHOOTING FOUND WIRE CONNECTORS AND TERMINAL BLOCK AT TB-AA IN DA PANEL OVERHEATED AND BURNED DUE TO IMPROPER TORQUE OF NUTS ON TERMINAL STUDS REQUIRING REPLACEMENT OF TERMINAL BLOCK AA, AND WIRES FROM AA1L AND AA2L TO CONNECTOR JA-P5 PINS A AND B.

CA101025007

ROBSIN

LYC   

ROBSIN

PLUG

LEAKING

9/9/2010

R44   

O540F1B5

D2111

D4871

HYD RESERVOIR

HYD RESERVOIR LEAKING FROM VENT PLUG. HYD RESERVOIR REPLACED.

CA100922010

ROBSIN

LYC   

 

IGNITION LEAD

CUT   

9/22/2010

R44   

O540F1B5

 

 

ENGINE

FOUND NR 1 CYL TOP LEAD CUT, SPARK PLUG NOT FIRING.

CA100716003

ROBSIN

LYC   

 

STARTER

FAILED

7/9/2010

R44RAVENII

IO540AE1A5

 

149HTEC

ENGINE

ACFT WAS EXPERIENCING POOR STARTS, STARTER REPLACED.

CA100722010

ROBSIN

LYC   

 

FCU   

RATCHETING

7/21/2010

R44RAVENII

IO540AE1A5

 

25766304

ENGINE

FUEL CONTROL UNIT WAS FOUND TO HAVE RATCHETY THROTTLE AND MIXTURE CONTROLS, REPLACED.

CA100805015

ROBSIN

LYC   

 

CLUTCH

FAILED

7/30/2010

R44RAVENII

IO540AE1A5

 

C0183

MAIN ROTOR

THE PILOT REPORTED A LOUD BANG AND A MOMENTARY YAW WHILE IN CRUISE FLIGHT. THE CLUTCH ASSY WAS REPLACED.

CA100713012

ROBSIN

LYC   

 

PUMP

LEAKING

7/6/2010

R44RAVENII

IO540AE1A5

 

D8187B

FUEL SYSTEM

FUEL PUMP FOUND LEAKING THROUGH DRAIN WHILE STATIC, REPLACED SERVICABLE.

CA100716002

ROBSIN

LYC   

 

RESERVOIR

LEAKING

7/9/2010

R44RAVENII

IO540AE1A5

 

D2112

HYD SYSTEM

DURING INSPECTION, THE HYD RESERVOIR FOUND LEAKING, RESERVOIR REPLACED.

CA100722009

ROBSIN

LYC   

 

STARTER

UNSERVICEABLE

7/19/2010

R44RAVENII

IO540AE1A5

 

14924HTH

ENGINE

STARTER WAS UNSERVICEABLE, REPLACED WITH A SERVICABLE STARTER.

CA101025008

ROBSIN

LYC   

 

PUMP

NOISY

10/14/2010

R44RAVENII

IO540AE1A5

 

D8187B

FUEL SYSTEM

ELECTRIC FUEL PUMP, PN D8187-B, (RHC PN: D743-1) NOISY. REPLACED FUEL PUMP.

CA101025009

ROBSIN

LYC   

ROBSIN

SWITCH

FAILED

10/10/2010

R44RAVENII

IO540AE1A5

C0512

C0531

CLUTCH ACTUATOR

SWITCH FAILURE. CLUTCH ACTUATOR ASSEMBLY REPLACED.

CA101027007

ROBSIN

LYC   

 

SPRAG ASSY

CRACKED

6/4/2010

R44RAVENII

IO540AE1A5

 

C1883

MAIN ROTOR

DURING T/O, BANG HEARD BY PILOT, ABORTED T/O. CONFIRMED SUSPECTED SPRAG FAILURE DIAGNOSIS WITH HELICOPTERS AND PILOTS REPORTED SYMPTOMS. CLUTCH ASSY REPLACED IN FIELD. DIAGNOSIS FURTHER CONFIRMED BY DIASSASEMBLY OF RETURNED SPRAG UNIT BY MFG.

CA100805014

ROBSIN

LYC   

 

CLUTCH

FAILED

7/29/2010

R44RAVENII

IO540AE1A5

 

C0183

MAIN ROTOR

THE PILOT REPORTED A LOUD BANG AND A MOMENTARY YAW WHILE IN CRUISE FLIGHT. THIS HAPPENED MORE THAN ONCE IN THE LAST 250 HRS. THE CLUTCH ASSY (FREEWHEEL) IS SUSPECTED TO HAVE SLIPPED IN FLIGHT. THE CLUTCH ASSY WAS REPLACED WITH NO RECURRENCE SINCE. WHILE FREE WHEELING BOTH CLUTCHES BY HAND, IT WAS NOTICED THAT THE OLD CLUTCH WAS ROUGH TO THE FEEL AND ALSO SOUNDED ROUGH COMPARED TO THE NEW ONE.

CA100804024

ROBSIN

LYC   

ROBSIN

BRACKET

LOOSE

3/18/2010

R44RAVENII

IO540AE1A5

 

 

BEARING SUPPORT

DURING FLIGHT, PILOT REPORTED A LOUD THUMP, THE CLUTCH LIGHT ILLUMINATED AND WOULD NOT GO OUT. INVESTIGATION FOUND THAT ALL 8 RIVETS ATTACHING THE LOWER ACTUATOR BEARING BRACKETS, TO THE FAN SCROLLS HAD SHEARED, ALLOWING THE LOWER ACTUATOR BRG TO COCK TO THE SIDE AND LOSE SOME TENSION ON THE DRIVE BELTS.

CA100806015

ROBSIN

LYC   

 

PUMP

SHORTED

6/24/2010

R44RAVENII

IO540AE1A5

 

RHCD7431

FUEL BOOST

THE ACFT CAME IN FOR A 50 HR INSP. THE BOOST PUMP WAS BLOWING THE CIRCUIT BREAKER. THE BOOST PUMP WAS REPLACED WITH A NEW ONE AND THE SYS TESTED SATISFACTORILY.

CA100722007

ROBSIN

LYC   

 

BEARING

LEAKING

7/15/2010

R44RAVENII

IO540AE1A5

 

C0174

SWASHPLATE

THE SWASHPLATE BEARING WAS LEAKING BLACK FLUID AND THE BEARING WAS FOUND LOOSE.

CA100713008

ROBSIN

LYC   

 

PUMP

LEAKING

7/7/2010

R44RAVENII

IO540AE1A5

 

LW15473

FUEL SYS

OIL FOUND LEAKING FROM BREATHER TUBE, FUEL PUMP REPLACED, SERVICABLE.

CA100706010

SKRSKY

ALLSN

 

DUCT

CHAFED

6/27/2010

S76A

250C30S

 

 

BLEED AIR SYS

IN CRUISE FLIGHT, WHEN CABIN HEATER WAS TURNED ON, OIL WAS BLOWN INTO THE COCKPIT CAUSING OIL MISTING ON THE WINDSHIELD AND COCKPIT FLOOR AT THE FOOT WARMERS, THE HOT BLEED AIR ALSO CAUSED THE OIL IN THE LINE TO SMOKE. HEATER WAS THEN SHUTOFF AND ACFT LANDED WITHOUT FURTHER INCIDENT. MX INSP REVEALED THAT THE BLEED AIR LINE IN THE NR 1 ENG BAY WAS CHAFED THROUGH FROM AN INCORRECTLY POSITIONED ENGINE PAN AT LAST ENGINE INSTALLATION. THE RESULTING 3 INCH BREECH OF THE LINE ALLOWED OIL FROM LEAKING SEALS TO RUN DOWN THE PAN AND INTO THE BREECH. BLEED AIR LINE WAS REPLACED AND THE ENGINE PAN REPOSITIONED, ACFT RETURNED TO SERVICE. OPERATOR CARRIED OUT FLEET WIDE INSP FOR LIKE PROBLEM (S).

BCYR20110217001

SKRSKY

 

 

PLANETARY GEAR

CRACKED

2/17/2011

S92A

 

 

9235115171101

UNKNOWN

OPERATOR DISCOVERED A LARGE CRACK THROUGH THE WEB SECTION OF THE PLANETARY GEAR WHILE CONDUCTING MPI EXAMINATION AS A NORMAL PART OF THE REPAIR PROCESS. MFG HAVE BEEN NOTIFIED AND THEY WILL BE CONDUCTING A FULL METALURGICAL INVESTIGATION.

QMLR20110311BL001

SNIAS

TMECA

 

BEAM

CHAFED

3/8/2011

AS350B3

ARRIEL1

 

350A21105120

ZONE 100

DURING SCHEDULED INSPECTION, SEVERAL LOCATIONS ON THE INBD SECTION OF BOTH AFT COMPATMENTS CHAFING WAS DISCOVERED. THE MFG HAS ISSED AN 8110-3 FOR THE REPAIRS NOTEING THAT THE MARGIN OF SAFETY HAS BEEN AFFECTED.

QMLR03112011BL002

SNIAS

TMECA

 

RING

DRILLED

3/8/2011

AS350B3

ARRIEL1B2

 

350A211247

AFT MIDDLE

DURING SCHEDULED INSP, AN ATTACHMENT POINT, IT WAS DISCOVERED A PARTIALLY MISDRILLED FASTENER HOLE. THE MFG HAS REVIEWED THIS ANOMALY AND ISSUED FAA FORM 8110-3 FOR THE REPAIR AND STATED THAT THE MARGIN OF SAFETY HAS NOT BEEN AFFECTED.

2011FA0000235

SOCATA

 

 

TEE FITTING

OBSTRUCTED

3/28/2011

TBM700

 

 

 

FUEL SYSTEM

FUEL PRESSURE INDICATION WENT OT -0- INFLIGHT. `FUEL PRESSURE LOW, ANNUNCIATOR REMAINED UNLIT. NO OPERATIONAL PROBLEMS NOTED. CLEANED ORIFICE IN PLUMBING TEE, ADJACENT TO FUEL PRESSURE TRANSDUCER, AND NORMAL INDICATION WAS RESTORED. THIS IS A RECURRING DIFFICULTY.

CA101001005

UROCOP

TMECA

 

MANIFOLD

FUMES

6/2/2010

EC120B

ARRIU2F

 

0319738330

EXHAUST

ALSO APPLIES TO LT MANIFOLD PN 0319738340 AND PREFERRED INJECTOR PN 0319738350 ALL TSN 51.5 EXHAUST FUMES IN CABIN RESULTING IN COMPLAINTS OF SORE THROAT, ITCHY EYES AND HEADACHE. REPLACED ALL COMPONENTS OF THE INJECTION MANIFOLD AND THE PROBLEM WAS CORRECTED. THIS STILL INDICATES THAT EXHAUST FUMES ARE ENTERING THE CABIN. CERTAIN INJECTORS HOWEVER CHANGE THE MIXTURE OF THE EXHAUST STREAM AND INCREASE THE HUMAN DETECTION THRESHOLD. THIS PHENOMENON HAS BEEN OBSERVED BY OTHER OPERATORS.

2011FA0000201

UROCOP

TMECA

 

SKIN

CRACKED

3/14/2011

EC120B

ARRIUS2F

 

 

TAILBOOM

DURING THE QC FINAL INSP PHASE OF A 100 HR INSP THE INSPECTOR NOTED A CRACK EXTENDING LONGITUDINALLY FWD AND AFT FROM THE LT FWD NAV/VOR ANTENNA MOUNT. PHOTO`S AND INFOR SENT TO MFG FOR DETERMINATION. MFG SUGGEST REMOVAL AND REPAIR BY MFG. BELIEVE PART TO BE WEAK IN THISE MOUNTING AREAS AND SUGGEST A REDESIGN OF THIS AREA TO PROVIDE ADDITIONAL SUPPORT.

QMLDMG2011A

UROCOP

 

 

WEB   

SEPARATED

3/22/2011

EC135T1

 

 

L533M1239107

CABIN FLOOR

THE COVER SHEET LH ASSEMBLY WAS FOUND MECHANICALLY SEVERED IN THE CENTER SECTION APPARENTLY FOR THE PURPOSE OF EASE OF REMOVAL AND REINSTALLATION IN THE COURSE OF MAINTENANCE.