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

364

bald eagle watching over three eggs

NOVEMBER

2008

 


CONTENTS

AIRPLANES

DASSAULT................................................................................................................................. 1

DIAMOND.................................................................................................................................. 1

MOONEY.................................................................................................................................... 2

WEATHERLY.............................................................................................................................. 2

HELICOPTERS

BELL............................................................................................................................................ 2

POWERPLANTS

HONEYWELL............................................................................................................................. 5

LYCOMING.............................................................................................................................. 15

P & W........................................................................................................................................ 18

PROPELLERS

SENSENICH............................................................................................................................. 19

AIR NOTES

INTERNET SERVICE DIFFICULTY REPORTING (iSDR) WEB SITE................................... 20

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

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

 

AIRPLANES

DASSAULT

Dassault: 900B; Failed Circuit Breaker; ATA 2400

A repair station report states, "While troubleshooting AC electrical outlets for being inoperative, (we) removed a floor panel to access the AC inverter and smelled burning plastic.  We found this system had self-resetting circuit breakers installed that had been (resetting themselves)—and were continuing to reset (themselves)—allowing the Klapton wire insulation and spiral wrap to burn.  One of the areas that burned was only three inches below a carbon flight control rod.  I believe had this happened on a very long flight the outcome could have been very tragic.   (It is suggested...) replacing these circuit breakers with (manually operated) circuit breakers would prevent the damage (which this report describes)."  (Original Part: Kilxon Circuit breaker; P/N M13516/5-1; aircraft total time not provided.)

Part Total Time: (unknown).

 

DIAMOND

Diamond: DA40F; Failed Carburetor Heat Control Arm; ATA 7160

(The following description combines two reports from two DA40 aircraft.  Both were submitted by the same mechanic.)

A mechanic states, "The carburetor heat control arm broke off the carburetor air box, causing uncontrolled selection of carburetor heat versus ram (cold) air intake.  I recommend installing thicker material on the carburetor heat control arm lever, or a different welding/heat treating process, or a different attachment provision altogether."  (P/N: D4F-7326-12-00-1)

Part Total Times: 12.7 and 30.9 hours (respectively).

 


Diamond: DA40F; Failed Electrical Fuel Pump; ATA 2822

(The following description combines nine reports from the same mechanic on five separate aircraft of the same model number.  Each aircraft is pulled by a Lycoming O360A4M.)

The submitter says, "After a previous flight (and before the next student's flight) the electric fuel pump was found to be inoperative.  Inadequate cooling is what we believe to be the source of the malfunction.  (Our suggested solution:) Provide ram for proper cooling of the fuel pump and motor.  (Electric fuel pump assembly: Dukes; P/N 5100-00-20.  Of the nine pumps the low time was 102.3 hours; a high time of 593.2 hours; an average time of 317.2 hours time since overhaul.  Truncating the last two digits from the part number yields 18 similar reports in the FAA Service Difficulty Reporting System database.

Part Total Time: (unknown).

 

MOONEY

Mooney: M20D; Inaccurate Fuel Gage; ATA 2841

An unknown submitter states, "(This aircraft's...) fuel gage indication is approximately 2.5 – 3.0 gallons higher than what is (actually) in the tank."  (Left fuel gage P/N: 5643860.  Left fuel tank transmitter P/N:5642354.  Given my dead-reckoning skills...I'd be calibrating that instrument today plus measuring how much goes in the tank every time—Ed.)

Part Total Time: 5,103.7 hours.

 

WEATHERLY

Weatherly: 620B; Cracked Aileron Spar; ATA 5751

"The left aileron spar," says an A&P mechanic, "is cracked at its center and at the outboard hinge bracket attach points.  (The cause is...) possibly due to the twisting effect of the aileron actuator being installed at the extreme inboard end of the aileron."  (Aileron P/N: 50846-006.)

Part Total Time: 1,890.0 hours.

 

HELICOPTERS

BELL

Bell: 212; Failed Main Rotor  Hub Grease Fittings; ATA 6220

A defect report submitted from Sweden states, "During lubrication of a Main Rotor Hub we discovered the spring in the grease fitting (P/N NAS516-1A) was pressed out from the fitting, blocking the grease passage.  This happened three times (during this lubrication procedure).  We found the springs after every attempt.  This (defect) could, for example, result in a loose spring in a rotating bearing, such as the swash plate."


THREE CLOSE-UP VIEWS OF THE GREASE FITTING INSERTS WITH LOOSE SPRINGS.

(Bell provided this related service letter back in 2003-Ed.)


 

BELL HELICOPTER TEXTRON INFORMATION LETTER GEN-03-88

 

Part Total Time: (unknown).

 


POWERPLANTS

HONEYWELL

Honeywell: TPE331-10R-511C; Bull-Gear Failure; ATA 7210

(There are M or D reports...and on rare occasions beautifully packaged engineering reports from which ripping the bare facts just doesn't seem appropriate—especially after this editor blundered page four with a yellow highlighter.  Only then did I think to ask for publishing permission.  Thank-you to Turbine Shop Manager Matt Hart of Tenix Aviation from way down under—Ed.)


 

TENEX AVIATION LTD PTY, FAA REPAIR STATION X1NY641X CASA C OF A C561713 TPE331 ENTINEERING REPORT.

ENGINE PICTURE ON REPORT'S FRONT PAGE


 

TPE331 ENTINEERING REPORT.


 

TPE331 ENTINEERING REPORT


TPE331 ENGINEERING REPORT.


TPE331 ENTINEERING REPORT.

PG. 5 OF 9: TWO CLOSE-UP VIEWS OF INSIDE DAMAGED GEARBOX.


TPE331 ENTINEERING REPORT.

PG. 6 OF 9: TWO CLOSE-UP VIEWS OF BROKEN GEARS.


TPE331 ENTINEERING REPORT.

PG. 7 OF 9: TWO CLOSE-UP VIEWS OF BROKEN bULL-GEAR.


TPE331 ENTINEERING REPORT.


PG. 8 OF 9: CUT-AWAY VIEW OF THE TPE331 ENGINE.


TPE331 ENGINEERING REPORT.

Part Total Time: 2,170. 6 hours.

 


LYCOMING

Lycoming: TIO-540-AJ1A; Loose Exhaust Stacks; ATA 7810

A repair station technician states, "During a Cessna 100 hour inspection, we found the exhaust stack at the number 2 cylinder pulled down approximately 1/16 inch.  Further investigation found the number 1, 3, 5 and 6 engine cylinder exhaust stacks also pulled down, but not as much."  "During the engine cylinder removal process we found the lower forward, ¾ inch stud nut under torqued.  Further investigation revealed the forward 2 studs (each) below Lycoming's recommended driving torque for cylinder hold-down studs in the case.  We installed new, oversized studs (0.003") as per the engine manufacturer's recommendations.  We installed the new, number 2 engine cylinder and new exhaust crossover pipe as required (see pictures).  Note: tightening the exhaust flange nuts does not stop the leak on all of the studs; on some of the studs the nut bottoms out on the threads.  After tightening, the previously effected exhaust flange areas have come loose again after 50 hours time in service."  (Exhaust assembly P/N: 40B222318.)

 

CLOSE-UP VIEW SHOWING A GAP UNDER THE EXHAUST MOUNTING NUT.


 

ANOTHER VIEW OF A CLOSE-UP VIEW SHOWING A GAP UNDER THE EXHAUST MOUNTING NUT.


 

ANOUTHER VIEW OF A CLOSE-UP VIEW SHOWING A GAP UNDER THE EXHAUST MOUNTING NUT WITH PAPER CARD DEMONSTRATING PRESENCE OF GAP.

 

Part Total Time: 98.1 hours.

 


P & W

P & W; PW500 Series; Number 4 Bearing Seal Distress; ATA 7250

(The following admonition is published here as received from Transport Canada.)

 

SERVICE DIFFICULTY ADVISORY FROM TRANSPORT CANADA.


 

LAST PAGE OF SERVICE DIFFICULTY ADVISORY FROM TRANSPORT CANADA.

 

Part Total Time: (n/a).

 

PROPELLERS

SENSENICH

Sensenich: S76EM & S74DM; Cracked Spinner Assemblies; ATA 6113

(This description combines five short defect reports on the two noted propeller spinner assemblies.  The S76 version has four reports associated with the Maule MXT-7-180 sporting a Lycoming O-360-C4F.  The S74 has one report belonging to the Maule MXT-7-160 with a Lycoming O-320-B2D.)

"The forward (spinner) bulkhead cracked through the mount bolt holes," says the A&P mechanic.  "This has occurred several times—I think it warrants action."

(The S76 bulkhead P/N: C2367, averaging 225 hours of the four reports; the S74 bulkhead P/N: C2365 ran 3,600 hours—or 16 times that of the former!)

Part Total Times: 225.0 (Avg.) and 3,600.0 hours (respectively).

 


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/.

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 address below.


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) 954-1150
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 (SDR) System 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. To view individual report go to the SDR query page and enter the control number of the record you wish to view: http://av-info.faa.gov/sdrx/query.aspx

Control Number
Difficulty Date

Aircraft Make
Aircraft Model

Engine Make
Engine Model

Component Make
Component Model

Part Name
Part Number

Part Condition
Part Location

2008FA0000645

 

 

 

BOLT

BROKEN

9/18/2008

 

 

 

A321

BLADE CLAMP

A-321 CLAMP BOLT WAS FOUND TO BE BROKEN DURING TEARDOWN INSPECTION. BOLT IS CRACKED IN (2) PIECES APPROXIMATELY .5 THE LENGTH DOWN THE TREADED AREA. CLAMP THAT IT WAS ATTACHED TO WAS LATER FOUND TO BE CRACKED DURING MAG PARTICLE INSPECTION. (K)

2008FA0000585

 

 

 

GENERATOR

FAILED

8/18/2008

 

 

 

11522185

 

FAILS SATURATION CURVE CHECK-ZERO VOLTS ANY PHASE. BROKEN LOWER CROSSOVER ON ROTOR. PENDING ENGINEERING EVALUATION. (K)

2008FA0000644

 

 

 

CLAMP

BROKEN

9/18/2008

 

 

 

A66315A

PROPELLER BLADE

BLADE CLAMP FOUND TO BE CRACKED DURING MAGNETIC PARTICLE INSPECTION. CRACK IS LOCATED IN REAR HALF EXTENDING FROM THE A-321 OUTER BOLT HOLE TO THE INSIDE OF THE CLAMP. DURING TEARDOWN INSPECTION, A-321 BOLT REMOVED FROM THIS CLAMP WAS BROKEN IN HALF. (K)

2008FA0000700

 

 

 

BLADE

CRACKED

7/18/2008

 

 

 

6607132886

PROPELLER

PROP RECEIVED FOR ROUTINE O/H. AFTER PROP WAS DISASSEMBLED IT WAS NOTED THAT BLADE NR 2, SN 1141 HAD A CRACKED ROOT END OUTER SLEEVE. BLADE IS REJECTED FROM FURTHER SERVICE. SB SF 340.60.A106 ADDRESSES THIS. (K)

2008FA0000632

 

CONT

MCAULY

DRIVE SYSTEM

BROKEN

9/11/2008

 

IO520*

 

B20429

 

SPRING-DRIVE DISCOVERED BROKEN AT DISASSEMBLY. (K)

2008FA0000694

 

CONT

MCAULY

SPRING DRIVE

BROKEN

9/11/2008

 

IO520*

 

B20429

GOVERNOR

SPRING DRIVE DISCOVERED BROKEN AT DISASSEMBLY. (K)

UIE2008F00036

 

GE

 

NONE

NONE

9/21/2008

 

CF650*

 

 

NONE

ATB. BOTH AUTOPILOTS A AND B WILL NOT ENGAGE (BOTH TESTED OK ON GROUND). A/P A AND B PITCH AND ROLL COMPUTERS, ASTU AND M AND LU BITE CHECK ALL OK. FLT CTL HYD POWER SHUT OFF SWITCHES ALL CHECKED IN ON POSITION. A/P ACCESS BOXES INSTALLATION SECURED. MSP ELECT CONNECTORS INSPECTION, NO FAULTS (SEE LOG PAGES). (K)

2008FA0000577

 

LYC

 

VALVE SEAT

DAMAGED

6/12/2008

 

IO360A1A

 

AEL12688P020

CYLINDER HEAD

INTAKE VALVE SEAT CAME LOOSE FROM THE SEAT BORE IN THE CYLINDER HEAD. THE LOOSE SEAT DAMAGE TO THE CYLINDER HEAD, VALVE, AND VALVE SEAT. INTERFERENCE FIT BETWEEN THE VALVE SEAT AND THE CYLINDER HEAD WAS NOT CORRECT. THIS WAS AN OVERHAULED CYLINDER. (K)

2008FA0000578

 

LYC

 

VALVE SEAT

DAMAGED

7/16/2008

 

IO360C1E6

 

AEL12688P020

CYLINDER HEAD

INTAKE VALVE SEAT CAME LOOSE FROM THE SEAT BORE IN THE CYLINDER HEAD. THE LOOSE SEAT DAMAGE TO CYLINDER HEAD, VALVE, AND VALVE SEAT. INTERFERENCE FIT BETWEEN THE VALVE SEAT AND THE CYLINDER HEAD WAS NOT CORRECT. THIS WAS AN OVERHAULED CYLINDER. (K)

2008FA0000586

 

LYC

 

PUSHROD

CRACKED

9/15/2008

 

O235L2C

 

TT73806

ENGINE

(3) PUSHRODS (TT73806) WERE INSTALLED IN THIS ENGINE AND ALL 3 HAD APPROXIMATELY A .3750 INCH VERTICAL CRACK ON BOTH ENDS. CAUSE UNKNOWN - NO RECOMMENDATIONS. (K)

2008FA0000730

 

PWA

 

BELLOWS

DAMAGED

9/3/2008

 

PT6A34AG

 

2523631

FCU

FCU (PN 32447866-6, SN B32178) BENCH TESTED AND FOUND TO BE UNSERVICEABLE DUE TO BREACHED BELLOWS, (PN 2523631, SN 8011). (K)

COEA0803919

AEROSP

 

 

SKIN

DAMAGED

8/22/2008

ATR42300

 

 

S53671205204

FUSELAGE

MAJOR REPAIR: DAMAGE TO AFT LT DOOR AND FUSELAGE. IMPACT DAMAGE TO LT AFT FUSELAGE SKIN DOUBLER PLATE AFT OF AFT PASSENGER DOOR. FUSELAGE SKIN DENTED WITH CRACKING FOUND AT ONE FASTENER. FUSELAGE SKIN DAMAGED AREA CUT OUT AROUND CRACKED FASTENER HOLE AND DOUBLER. (K)

COEA0803912

AEROSP

 

 

INDICATOR

FAILED

9/5/2008

ATR42300

 

 

457400TB0811

VSI/TCAS

AIR TURN BACK, ENROUTE, THE CAPT`S VSI FLASHED MOMENTARILY CAUSING A TCAS FAIL AND RESOLUTION ALERT, THEN WENT BLANK. SINCE THE COPILOT`S SYSTEM WAS OPERATING NORMALLY. A DECISION TO RETURN TO DEPARTURE WAS MADE SINCE PARTS WERE AVAILABLE THERE AND MAINTENANCE ALSO COULD BE ACCOMPLISHED. REMOVED AND REPLACED CAPT`S VSI/TCAS INDICATOR. (K)

F3LA200800607

AIRBUS

 

 

PANEL

PUNCTURED

9/12/2008

A319111

 

 

D53673020000000

CARGO BAY

REFERENCE NON-ROUTINE C050860. DURING C3-C-CHECK, INSPECTION NOTED THE AFT PIT TRANSITION PANEL 151BE WAS DAMAGED. MAINTENANCE REPAIRED DAMAGED FLOOR PANEL IAW THE REQUIREMENTS OF A319 SRM 53-02-00, FIGURE 204. UPON COMPLETION OF THE REPAIR, IT WAS INSPECTED AND FOUND ACCEPTANCE. (K)

 

 

F3L2008F00005

AIRBUS

 

 

FLOOR SUPPORT

CORRODED

9/6/2008

A319111

 

 

D5347217220400

FUSELAGE

REF: NON ROUTINE C050602. DURING C3 C-CHECK, INSPECTION NOTED SEVERAL NUT PLATE HOLES ON FRAME Y-1292 BETWEEN FRAME 66 AND FRAME 68, HAD CORROSION. MAINTENANCE REMOVED AND REPLACED FLOORBEAM IAW WITH THE REQUIREMENTS OF A319 SRM 51-42-11. UPON COMPLETION OF THE REPAIR, IT WAS INSPECTED AND FOUND ACCEPTABLE. (K)

F3LA200800600

AIRBUS

 

 

FLOORBEAM

CORRODED

9/6/2008

A319111

 

 

D53472172202

FUSELAGE

REF NON ROUTINE C050600. DURING C3 C-CHECK, INSPECTION NOTED FWD NUT PLATE HOLE ON FRAME Y-1292 AT FRAME 66, HAD CORROSION. MAINT REMOVED CORROSION FROM HOLE, FABRICATED REPAIR BUSHING AND INSTALLED IAW WITH THE REQUIREMENTS OF ENGINEERING AUTHORIZATION NR A9-53R-30598. UPON COMPLETION OF THE REPAIR, IT WAS INSPECTED AND FOUND ACCEPTABLE. (K)

F3LA200800609

AIRBUS

 

 

FLOORBEAM

CORRODED

9/16/2008

A319111

 

 

D53472172220500

FUSELAGE

DURING C3 C-CHECK, INSPECTION NOTED THE FLOORBEAM IB OF THE R2 DOOR SILL HAS CORROSION IN ALL NUT PLATE HOLES. MAINT REMOVED AND REPLACED FLOORBEAM. Y1292 IAW THE REQUIREMENTS OF A319 SRM 51-42-11. UPON COMPLETION OF THE REPAIR, IT WAS INSPECTED AND FOUND ACCEPTABLE. (K)

F3LA200800605

AIRBUS

 

 

SKIN

DENTED

9/7/2008

A319111

 

 

 

FUSELAGE

REF NON ROUTINE C00003. DURING EXIT CHECK, INSPECTION NOTED THE AC INCURRED A BIRD STRIKE CAUSING A DENT IN THE FUSELAGE SKIN BELOW THE RT COCKPIT WINDSHIELD. THE DENT MEASURED 2 INCHES WIDE AND 2 INCHES LONG BY .1250 INCH DEEP. MAINT PERFORMED A DETAILED VISUAL INSPECTION OF THE AFFECTED AREA, A HIGH FREQUENCY EDDY CURRENT INSPECTION OF ADJACENT FASTENERS AND RECONTOURED THE AREA OF SKIN DAMAGE. MAINT WAS ACCOMPLISHED IAW THE REQUIREMENTS OF ENGINEERING AUTHORIZATION NR A9-53R-30586, WHICH CLASSIFIED THE REPAIR AS "MAJOR". UPON COMPLETION OF THE REPAIR, IT WAS INSPECTED AND FOUND ACCEPTABLE. (K)

F3LA200800604

AIRBUS

 

 

FLOOR PANEL

CORRODED

9/8/2008

A319111

 

 

D5367175500000

FUSELAGE

REF: NON ROUTINE C050752. DURING C3 C-CHECK, INSPECTION FOUND (1) MOUNT BUSHING CORRODED ON FLOOR PANEL 261DE. MAINTENANCE REMOVED AND REPLACED MOUNT BUSHING ON C-CHECK CARD NR C5341032. UPON COMPLETION OF THE REPAIR, IT WAS INSPECTED AND FOUND ACCEPTABLE. (K)

F3LA200800603

AIRBUS

 

 

HINGE

DAMAGED

9/3/2008

A319111

 

 

D57745013

RT WING SPOILER

REF: NOT ROUTINE C050745. DURING C3 C-CHECK, INSPECTION FOUND DAMAGE ON THE RT NR (2) SPOILER ANTI-ROTATION WEB. MAINT MACHINED AREA, FABRICATED REINFORCING PLATE AND PROTECTED AREA IAW ENGINEERING AUTHORIZATION NR A9-57R-30610. UPON COMPLETION OF THE REPAIR, IT WAS INSPECTED AND FOUND ACCEPTABLE. (K)

F3LA200800602

AIRBUS

 

 

HINGE

DAMAGED

9/3/2008

A319111

 

 

D57745013

RT WING SPOILER

REF NON ROUTINE C050746. DURING C3 C-CHECK, INSP FOUND DAMAGE ON THE RT NR (4) SPOILER ANTI-ROTATION WEB. MAINT MACHINED AREA, FABRICATED REINFORCING PLATE AND PROTECTED AREA IAW EA NR A9-57R-30609. UPON COMPLETION OF THE REPAIR, IT WAS INSPECTED AND FOUND ACCEPTABLE. (K)

F3LA200800599

AIRBUS

 

 

FLOORBEAM

CORRODED

9/4/2008

A319111

 

 

D53472172203

FUSELAGE

REF NON ROUTINE C050605. DURING C3 C-CHECK, INSPECTION NOTED SEVERAL NUT PLATE HOLES ON FRAME Y-1292 BETWEEN FRAME 66 AND FRAME 68, HAD CORROSION. MAINT REMOVED CORROSION FROM HOLES, FABRICATED REPAIR PROFILE AND FILLER, AND INSTALLED IAW THE REQUIREMENTS OF EA NR A9-53R-30604 AND A 319 SRM 53-00-14, FIGURE 214. UPON COMPLETION OF THE REPAIR, IT WAS INSPECTED AND FOUND ACCEPTABLE. (K)

F3LA200800610

AIRBUS

 

 

SHEAR PLATE

CORRODED

9/16/2008

A319111

 

 

D5347112420100

FUSELAGE

REFERENCE NOT ROUTINE C051378. DURING C3 C-CHECK, INSP NOTED THE RT SHEAR PLATE FROM FR 69 TO FRAME 70 WAS CORRODED. MAINT REMOVED AND REPLACED SHEAR PLATE ASSY AND SUPPORT FRAME IAW THE REQUIREMENTS OF A319, SRM 51-42-11, PARA 6 AND 7. UPON COMPLETION OF THE REPAIR, IT WAS INSPECTED AND FOUND ACCEPTABLE. (K)

F3LA200800606

AIRBUS

 

 

PANEL

PUNCTURED

9/12/2008

A319111

 

 

D5367314400000

FUSELAGE

REFERENCE NON-ROUTINE C050859. DURING C3 C-CHECK. INSPECTION NOTED THE AFT PIT TRANSITION PANEL 151FE WAS DAMAGED. MAINTENANCE REPAIRED DAMAGED FLOOR PANEL IAW THE REQUIREMENTS OF A319 SRM 53-02-00, FIGURE 204. UPON COMPLETION OF THE REPAIR. IT WAS INSPECTED AND FOUND ACCEPTABLE. (K)

F3LA200800608

AIRBUS

 

 

PANEL

PUNCTURED

9/12/2008

A319111

 

 

D5367301900000

FUSELAGE

REF NON-ROUTINE C050863. DURING C3-C-CHECK. INSP NOTED THE AFT PIT TRANSITION PANEL 151TG WAS DAMAGED. MAINT REPAIRED DAMAGED FLOOR PANEL IAW WITH THE REQUIREMENTS OF SRM 53-02-00, FIGURE 204. UPON COMPLETION OF THE REPAIR. IT WAS INSPECTED AND FOUND ACCEPTABLE. (K)

USAA920081669

AIRBUS

 

 

PIN

CORRODED

8/16/2008

A319112

 

 

D3215303000800

MLG

MINOR CORROSION ON AFT FACE OF LANDING GEAR PINTAL PIN. REPLACED LANDING GEAR PINTAL PIN. (K)

USAA920081663

AIRBUS

 

 

CONTROL UNIT

FAULTY

9/8/2008

A320214

 

 

C202163392E34

NLG STEERING

EMERGENCY LANDING- FLIGHT DEPARTED WITH BSCU SYS, BRK/STEER MEL 32-42-03A. WHILE ENROUTE, SECOND CHANNEL WAS LOST. CREW DECLARED AN EMERGENCY AND RETURNED TO DEPARTURE. MAINT REMOVED AND REPLACED THE BRAKE/STEERING CONTROL UNIT IAW MM 32-42-34. OPS CHECK WAS NORMAL. (K)

VQI2008F00003

AIRBUS

CFMINT

 

CONTROLLER

FAILED

8/23/2008

A320214

CFM565B4

 

31077100

LT NR 5 SPOILER

FLIGHT PHASE 6 CLIMB DEPARTED JFK AT 1127 Z - RETURNED TO FIELD AT 1200 Z. CREW REPORTED A NORMAL DEPARTURE WITH NO ABNORMALITIES UNTIL AROUND 10,000 FT WHEN THEY NOTICED AN AIRFRAME VIBRATION. CHECKING WITH THE FLT TEAM, THEY CONFIRMED THAT A CREW REPORTED A NORMAL DEPARTURE WITH NO ABNORMALITIES UNTIL AROUND 10,000 FT WHEN THEY NOTICED AN AIRFRAME VIBRATION. CHECKING WITH THE IN FLIGHT TEAM, THEY CONFIRMED THAT A LT NR 5 SPOILER HAD PARTIALLY DEPLOYED. THE AC RETURNED TO DEPARTURE WITH AN UNEVENTFUL LANDING. THE NR 5 SPOILER HAD MEL 27-64-01-2 APPLIED PRIOR TO DEPARTURE. THE NR 5 SPOILERS WERE LOCKED OUT IAW MEL MAINT PROCEDURE. AFTER RETURN, THE LT SPOILER SERVO CONTROL WAS REPLACED. THE ORIGINAL FAULT CONTINUED AND THE NEW SPOILER SERVO CONTROL WAS LOCKED OUT. LATER T/S HAS LED TO A TERMINAL BLOCK PROBLEM WHICH IS SCHEDULED FOR REPLACEMENT. THE REMOVED SPOILER SERVO CONTROL IS QUARANTINED AND UNDER EXPEDITION FOR SHOP TEAR DOWN AND INVESTIGATION. THIS SPOILER SERVO CONTROL SN 3829 WAS INSTALLED ON 08/08/08. IT IS PRE-MOD SBA 320-27-1109. INVESTIGATIONS HAVE BEEN INITIATED AND MORE INFORMATION WILL BE FORTHCOMING AS IT BECOMES AVAILABLE. ROOT CAUSE: THE ROOT CAUSE HAS BEEN DETERMINED TO BE IMPROPER LOCK OUT OF THE SPOILER SERVO CONTROL BY TECH DUE TO THE PRE-MOD PART 31077-100 BEING INSTALLED ON THE ACFT ON 08/08/2008. THE MODIFICATION IS DATED SEPT 1997 AND IS DESIGNED TO PREVENT IMPROPER LOCKOUT OF THE UNIT. THE -100 PART HAS BEEN REPLACED WITH THE STANDARD -111 UNIT AND PRE-MOD SPOILER SERVO CONTROLS ARE NO LONGER ALLOWED TO BE INSTALLED. THE TECH HAD NOT ENCOUNTERED A PRE-MOD UNIT BEFORE. MEL MAINT PROCEDURES HAVE BEEN REVIEWED AND FOUND TO BE VALID. (K)

USAA920081662

AIRBUS

 

 

POWER SUPPLY

DEFECTIVE

9/10/2008

A320231

 

 

32145410

EMERGENCY LIGHTS

EMERGENCY LIGHTS INTERMITTENTLY INOPERATIVE. MAINT REMOVED AND REPLACED THE MID CABIN EMERGENCY POWER SUPPLY IAW MM 33-51-38. OPS CHECK WAS GOOD. (K)

 

 

USAA920081909

AIRBUS

 

 

FLAP SYSTEM

FROZEN

10/16/2008

A320232

 

 

 

 

EMERGENCY LANDING - FLIGHT WAS ON APPROACH WHEN THE FLAPS FROZE AT 2 DEGREES. THE CAPTAIN DECLARED AN EMERGENCY AND LANDED WITHOUT INCIDENT. MAINT DETERMINED FLAPS EXTENSION AND RETRACTION TO BE NORMAL. (K)

YENA2008088

AIRBUS

 

 

UNKNOWN

ODOR

9/11/2008

A320232

 

 

 

GALLEY

DURING CRUISING, F/A DETECTED AN ODOR OF SMOKE IN AFT GALLEY. TURNED AFT RACK POWER OFF AND ODOR WENT AWAY. ACCOMPLISHED TSM 23-39-00 AND NO DEFECT NOTED. ALL SYSTEM OPERATES WITH NO EVIDENCE OF SMOKE.

USAA920081907

AIRBUS

 

 

FAN

DEFECTIVE

10/19/2008

A320232

 

 

EVT3454H

ZONE 100

AIR TURNBACK, CREW SENT A CARS MESSAGE REPORTING BLOWER FAN FAULT AND FUMES IN THE COCKPIT. CAPTAIN DONNED O2 MASK AND DECLARED AN EMERGENCY. ACFT RETURNED TO DEPARTURE AND LANDED WITHOUT INCIDENT. MAINT REMOVED AND REPLACED THE AVIONICS VENT BLOWER FAN IAW MM 21-26-51. (K)

USAA920081679

AIRBUS

 

 

FLASHLIGHT

INOPERATIVE

9/12/2008

A320232

 

 

P2070003001

ZONE 200

AFT F/A FLASHLIGHT INOPERATIVE. REMOVED AND REPLACED AFT F/A FLASHLIGHT. OPERATIONAL CHECK WAS GOOD. (K)

YENA2008090

AIRBUS

 

 

UNKNOWN

ODOR

9/18/2008

A320232

 

 

 

CABIN

PASSING 8000 FEET ON CLIMB OUT, PASSENGER AND CREW DETECTED AN ODOR ORIGINATING IN THE AREA OF ROW 4, ODOR WAS NOTICED FROM FLIGHT DECK TO ROW 20. AIRCRAFT RETURNED FOR INSPECTION. ODOR DECREASED AFTER LANDING. LANDING WEIGHT 138,000 LBS. PERFORMED TASK 24-00-00-810-823 AND TASK 23-39-810-801. NO DEFECTS NOTED. REPLACED RECIRCULATION FILTER PRECAUTIONARY IAW AMM 21-21-41. NO OTHER DEFECTS NOTED AIRCRAFT OK FOR SERVICE. (K)

USAA920081908

AIRBUS

 

 

CYLINDER

BLOWN

10/19/2008

A321211

 

 

FE240004

DOOR ASSIST

EMERGENCY EQUIPMENT - MAINT FOUND DOOR ASSIST BOTTLE BLOWN ON FWD LEFT DOOR. REMOVED AND REPLACED DOOR DAMPER CYLINDER IAW MM 52-11-14. (K)

USAA920081664

AIRBUS

 

 

FUEL SYS

MALFUNCTIONED

9/8/2008

A321211

 

 

 

CNTR TANK XFER

CREW RECEIVED ECAM FUEL ACTUATOR TRANSFER FAULT IN CRUISE AND ADVISED DISPATCH THAT FUEL HAD BECOME TRAPPED IN THE ADDITIONAL CENTER TANK. CREW PERFORMED QRH PROCEDURES BUT THE MANUAL TRANSFER ATTEMPT WAS UNSUCCESSFUL. FLIGHT DIVERTED AND LANDED WITH INCIDENT. (K)

USAA920081667

AIRBUS

 

 

WARNING LIGHT

ILLUMINATED

9/11/2008

A321211

 

 

 

SLIDE BOTTLE

EMERGENCY EQUIPMENT - CIDS PANEL CAUTION FOR SLIDE BOTTLE EXIT RT GAUGE READS PRESSURE IN GREEN. MAINT REMOVED AND REPLACED THE R3 SLIDE BOTTLE IAW MM 25-62-49-00-001. (K)

2008FA0000652

AIRTRC

PWA

 

ENGINE

STOPPED

8/22/2008

AT301

R1340*

 

 

 

ENGINE QUIT IN MID-AIR. ENGINE HAD 1195.0 HOURS SINCE MAJOR OVERHAUL. (K)

2008FA0000597

AMD

CFE

 

SUPPORT

CRACKED

8/26/2008

FALCON2000

CFE73811B

 

305086010

NR 4 BEARING

THE NR 4 BEARING SUPPORT, PN 305086010, CRACKED CAUSING THE ENGINE TO SEIZE. AT OPERATING TEMPERATURES, THE NR 4 BEARING SUPPORT AND INVESTMENTCAST MANIFOLD MAY HAVE BECAME LOOSE, PERMITTING RELATIVE MOVEMENT BETWEEN THE PARTS. SB CEF738-72-8060 REPLACES THE NR 4 BEARING SUPPORT WITH SUPPORT ASSY PN 305086012, WHICH HAS BEEN DESIGNED WITH AN INCREASED INTERFERENCE FIT TO ELIMINATE MOVEMENT. (K)

ZES2008F00000

AMD

PWC

 

CASE

CORRODED

7/9/2008

FALCON2000

PW308A

 

30C4656C

DIFFUSER

ABORTED TAKEOFF, DUE TO RT ENGINE CHIP LIGHT. REMOVED CHIP PLUG FOR INSPECTION, FOUND SMALL DEBRIS, CLEANED, DRAINED AND FLUSHED OIL SYS, INSPECTED OIL FILTER, FOUND NO SIGNIFICANT CONTAMINATION. REINSTALLED FILTER AND SERVICED OIL. GROUND RUN, FOUND NO CHIP LIGHT DURING RUN. DIFFUSER CORRODED. (K)

ZES2008F00001

AMD

PWC

 

DIFFUSER

CORRODED

9/8/2008

FALCON2000

PW308C

 

30C4656C

ENGINE

DURING ENGINE START OIL PRESSURE REMAINED AT ZERO PSI WITH A LOW OIL PRESSURE LIGHT WHEN ENGINE REACHED IDLE. SHUT DOWN ENGINE. INVESTIGATION REVEALED THE ENGINE DRIVEN HYDRAULIC PUMP LOCKED UP DUE TO A PIECE OF METAL THAT HAD DETACHED FROM THE DIFFUSER CASE THAT SUPPORTS THE NR3 MAIN BEARING. GOT INTO THE OIL SYS, SLIPPED BRG THE INLET SCREEN TO THE PUMP. (K)

2008FA0000684

AMD

 

 

POSITION SWITCH

INOPERATIVE

9/17/2008

FALCON20C5

 

 

A223801

MLG

LANDING GEAR FAILED TO RETRACT AFTER TAKEOFF. (K)

2008FA0000642

AMD

GARRTT

 

CONTROL SWITCH

INOPERATIVE

9/19/2008

FALCON20C5

TFE7315BR

 

123371

MLG

LANDING GEAR FAILED TO RETRACT AFTER TAKEOFF. (K)

2008FA0000683

AMD

GARRTT

 

LANDING GEAR

FAILED

9/19/2008

FALCON20C5

TFE7315BR

 

 

 

LANDING GEAR FAILED TO RETRACT AFTER TAKEOFF. (K)

 

 

2008FA0000641

AMD

GARRTT

 

SWITCH

INOPERATIVE

9/17/2008

FALCON20C5

TFE7315BR

 

A223801

MLG

LANDING GEAR FAILED TO RETRACT AFTER TAKEOFF. (K)

2008FA0000621

AMD

GARRTT

 

COMPRESSOR WHEEL

SEPARATED

8/26/2008

FALCON900EX

TFE73160

 

307241613

ENGINE

THE CREW REPORTED VIBRATION AND ITT RISE. POWER WAS PULLED BACK TO IDLE AND THE AC LANDED WITHOUT INCIDENCE. DISASSEMBLY FINDINGS REVEALED THE LPC2 ROTOR ASSY (PN 307241613). DISC PN 30603731, SN 990316003093, EXHIBITED MATERIAL LOSS IN THE FORM OF A DISC POST SEPARATION. (K)

EXD2008F00000

AMD

GE

 

PUMP

FAILED

8/21/2008

FALCOND

CF7002D2

 

9234A7

LT ENGINE

THE FLIGHT CREW REPORTED APPROXIMATELY (1) HOUR INTO THE FLIGHT, THE LT ENGINE SHUT DOWN WITH NO WARNING OR PRIOR INDICATION OF A PROBLEM. THE TREND MONITORING WAS COMPLETED PRIOR TO THE ENGINE PARAMETERS WERE NORMAL. THE FLIGHT CREW PROMPTLY NOTIFIED ATC AND LANDED WITHOUT FURTHER INCIDENT. MECHANIC WAS DISPATCHED WITH PARTS. AC FLIGHT LOG PAGE NR 1655, THE LT FUEL CONTROL UNIT AND THE LT FUEL PUMP WERE REMOVED AND REPLACED WITH SERVICEABLE UNITS, OPS AND LEAK CHECK GOOD AND THE ENGINE POWER RUNS WERE PERFORMED IAW MM CHAPTER 72. NO DEFECTS NOTED. AC WAS RETURNED TO SERVICE. (K)

2008FA0000637

AMRGEN

 

 

ANGLE

CRACKED

9/2/2008

AA5B

 

 

510229615

HORIZONTAL STAB

MAINT NOTICED A CLICKING NOISE AND EXCESSIVE MOVEMENT WHEN APPLYING UP AND DOWN PRESSURE TO HORIZONTAL STABILIZER TIPS. FOUND DELAMINATION, CRACKS AND WRINKLES IN HORIZONTAL STAB FWD SPAR CARRY-THROUGH ATTACH ANGLES INSIDE EMPENNAGE. WE BELIEVE THE SINGLE MOST CAUSE TO BE PILOTS AND MAINT PUSHING DOWN ON THE FWD SSPAR AREA TO RAISE THE NOSEWHEEL OFF THE GROUND. (K)

2008FA0000638

AMRGEN

 

 

ANGLE

CRACKED

9/2/2008

AA5B

 

 

510229616

HORIZONTAL STAB

MAINT NOTICED A CLICKING NOISE AND EXCESSIVE MOVEMENT WHEN APPLYING UP AND DOWN PRESSURE TO HORIZONTAL STABILIZER TIPS. FOUND DELAMINATION, CRACKS, AND WRINKLES IN HORIZONTAL STAB FORWARD SPAR CARRY-THROUGH ATTACH ANGLES INSIDE EMPENNAGE. WE BELIEVE THE SINGLE-MOST CAUSE TO BE PILOTS AND MAINTENANCE PUSHING DOWN ON THE FWD SPAR AREA TO RAISE THE NOSEWHEEL OFF THE GROUND. (K)

2008FA0000604

AMTR

 

 

CANOPY

DAMAGED

8/14/2008

CH601XL

 

 

 

COCKPIT

CANOPY OPENED IN FLIGHT RESULTING IN THE ACFT ENTERING INTO A NOSE DIVE ATTITUDE AND IMPACTING THE GROUND SERIOUSLY INJURING ONE PILOT AND MINOR INJURIES TO THE OTHER PILOT. THE CANOPY’S LOCKING MECHANISMS AND OVERALL STRUCTURE DO NOT SEEM RELIABLE. THE LT AND RT LATCHING POINTS BOLTS DO NOT APPEAR TO BE LONG ENOUGH AND/OR PROVIDE ENOUGH MATERIAL FOR THE CANOPY LOCKS TO LATCH DOWN ON. THE CANOPY PLEXIGLASS IS VERY THIN AND COVERS A LARGE CANOPY AIRFRAME AREA WHICH MAKES THE CANOPY LOOSE AND WOBBLY. THE TWO GASEOUS RETRACT/ EXTEND SHOCKS ON EACH SIDE OF THE FWD CANOPY ALSO APPEAR TO BE TOO STRONG (40 PSI EACH) WHICH MAY CAUSE THE CANOPY TO HAVE A TENDENCY TO EXTEND IN THE OPEN POSITION IN FLIGHT. IN GENERAL, THE CANOPY APPEARS TO BE TOO LARGE AND UNSTABLE FOR THE DESIGN. (K)

WIW2008F00000

AYRES

GARRTT

 

TORQUE SENSOR

FAILED

8/13/2008

S2RHGT65

TPE33110

 

31017262

ENGINE

ON 8/13/2008 AT APPROX 07:40 AM, AIRPLANE WHILE PERFORMING AERIAL APPLICATION EXPERIENCED A LOSS OF ENGINE POWER AND MADE AN EMERGENCY LANDING IN A FIELD. SUBSEQUENT INVESTIAGATION REVEALED THE IDLER GEAR BRG (PN 3103035-1) IN THE TORQUE SENSOR HAD FAILED ALLOWING THE LOSS OF DRIVE INPUT TO THE FUEL CONTROL RESULTING IN LOSS OF ENGINE POWER AND EMERGENCY LANDING. (K)

ZJ62008F00000

BAG

 

 

BOOT

MISSING

9/5/2008

JETSTM3101

 

 

SMR6890

PROP BLADE

NR 1 ENGINE VIBRATION IN FLIGHT, DEICE BOOT MISSING.

2008FA0000659

BBAVIA

 

 

SEAT

FAILED

9/16/2008

8KCAB

 

 

71500

CABIN

REAR SEAT PN 7-1500 FAILED AT THE LT HINGE POINT. THE AN3 SERIES BOLT PULLED THRU THE HINGE LUGS WHICH ARE WELDED TO THE SEAT FRAME BOTTOM. THE RT HINGE HOLES SHOW ELONGATION, BUT REMAINED INTACT. THE AC WAS DOING SPIN TRAINING AT THE TIME OF THE INCIDENT. RECOMMEND THAT THE SEAT FRAME BE MODIFIED TO CURRENT STANDARDS INSTALLED ON NEWER AC. (K)

GUU2008F00062

BEECH

 

 

DOOR

LACK OF LUBE

9/14/2008

1900D

 

 

 

EMERGENCY EXIT

DURING SCHEDULED ROUTINE MAINT DISCOVERED SEAT 6F EMERGENCY EXIT HARD TO OPEN. LUBED EMERGENCY EXIT. OPS CHECK GOOD. (K)

GUU2008F00051

BEECH

 

 

BRAKE ASSY

MALFUNCTIONED

8/31/2008

1900D

 

 

 

MLG

PILOT REPORTED NO BRAKES AND NO STEERING AT THE END OF LANDING ROLL. PERFORMED PRESSURE POT BLEEDING OF BRAKE SYSTEM. OPERATIONAL CHECK OF BRAKES AND STEERING NORMAL. (K)

GLB2008F00019

BEECH

 

 

FRAME

CRACKED

9/2/2008

1900D

 

 

 

FS 164.4 S9AR

DURING STRUCTURAL INSPECTION MAINT FOUND FRAME CRACKED AT STRINGER CUTOUT AT FS 164.4 STRINGER 9AR. LENGTH OF CRACK APPROXIMATELY .5 INCH. OPEN (K)

GUU2008F00064

BEECH

 

 

UNKNOWN

ODOR

9/10/2008

1900D

 

 

 

CABIN

DURING APPROACH VERY STRONG ODOR COMING FROM CABIN VENTS REGARDLESS OF MODE CONTROL SETTING. RAN ENGINES FOR 30 MINUTES AT ALL POWER SETTINGS AND MODE CONTROL SETTINGS NO ODOR NOTED. (K)

GUU2008F00050

BEECH

 

 

UNKNOWN

LEAKING

8/10/2008

1900D

 

 

 

 

DURING FLIGHT, STRONG FUEL ODOR IN CABIN, MADE PASSENGER SICK. REMOVED AND CLEANED OLD SEALANT AT SUSPECTED FUEL LEAK AREA AND RESEALED. NO LEAKS NOTED. (K)

GLB2008F00025

BEECH

 

 

FRAME

CRACKED

9/2/2008

1900D

 

 

 

BS 164 S9R

DURING STRUCTURAL INSPECTION MAINT FOUND FRAME CRACKED AT STRINGER CUTOUT AT FS 164.4 STRINGER 9AR. LENGTH OF CRACK APPROXIMATELY .5". MAINT REPAIRED FRAME CRACK AT STRINGER RELIEF HOLE IAW SRM 51-70 AT FS 164.4 REPAIR APPROXIMATELY 5 INCH BY 2.5 INCH. 2024-T3. RLL INSPECTION COMPLIED IAW TASKCARD 8.2.1. (K)

 

 

GLB2008F00018

BEECH

 

 

SWITCH

OUT OF ADJUST

8/28/2008

1900D

 

 

 

AUTOFEATHER

SUSPECTED AUTOFEATHER EVENT. DURING CRUISE, THE PILOTS REPORTED THAT THE LT AUTOFEATHER DISARMED IN FLIGHT AND NEVER REARMED AT ANY POWER SETTING. MAIT ADJUSTED THE LT POWER LEVER SWITCH. OPS CHECK OF THE AUTOFEATHER SYS GOOD IAW MM 61-20-00. (K)

GUU2008F00046

BEECH

 

 

CAM

OBSTRUCTED

8/25/2008

1900D

 

 

 

PAX DOOR

CABIN DOOR RT SIDE SECOND CAM FROM TOP IS RUBBING ON CAM LOCK MAKING DOOR HARD TO OPEN AND CLOSE. CLEANED EXCESSIVE GREASE AND GUM OUT OF CAM. (K)

GLB2008F00031

BEECH

 

 

MOTOR

BURNED

9/2/2008

1900D

 

 

1005240731

TE FLAP

PILOTS REPORTED A STRONG ODOR OF SMOKE WITH EYE IRRITATION PRESENT ON TAXI. TURNING OFF BLEEDS TO ENVIRO OFF AS WELL AS TURNING OFF MODE CONTROL, DID NOT CHANGE ODOR . THERE WAS NO VISIBLE SMOKE. MAINT TROUBLESHOT AND FOUND THE SMOKE ODOR TO BE A FLAP MOTOR THAT WAS BURNED INTERNALLY AND CAUSED FLAP MOTOR CIRCUIT BREAKER TO POP. MAIT PLACED THE ITEM ON MEL 27-2 CAT.B C/N NR 31666. (K)

GUU2008F00048

BEECH

 

 

UNKNOWN

ODOR

9/9/2008

1900D

 

 

 

COCKPIT

DURING FINAL APPROACH BOTH PILOTS OBSERVED BURNING ODOR. INSPECTED COCKPIT INSTRUMENTS NO DEFECTS NOTED, PERFORMED OPERATIONAL CHECK OF ENVIRONMENTAL SYSTEM COULD NOT DUPLICATE. (K)

GLB2008F00021

BEECH

 

 

CONNECTOR

LOOSE

8/26/2008

1900D

 

 

 

PCB

SUSPECTED AUTOFEATHER EVENT, UPON APPROACH, PILOTS REPORTED THAT RT AUTOFEATHER ACTUATED (AS IT NORMALLY DOES DURING TESTING) ON APPROACH AFTER A MINOR POWER INCREASE. MAINT REMOVED AND REPLACED THE OVERSPEED GOVERNOR IAW MM 61-20. OPS CHECK WAS GOOD, HOWEVER, IT DID NOT FIX THE DISCREPANCY. MAINT REMOVED AND REPLACED THE PRESSURE SWITCH PN 50-389121-4 IAW MM 61-21. SWITCH OPS CHECK GOOD, BUT DID NOT FIX THE DISCREPANCY. MX FOUND LOOSE SOCKET ON PCB A123 CONNECTOR. SECURED SOCKET, SYSTEM OPERATIONALLY CHECKED GOOD IAW MM 61-20. OPS CHECK FLIGHT WAS PERFORMED AND WAS SATISFACTORY. (K)

GUU2008F00049

BEECH

 

 

DOOR

OUT OF ADJUST

9/10/2008

1900D

 

 

 

EMERGENCY EXIT

DURING SCHEDULED ROUTINE MAINT, DISCOVERED LT EMERGENCY EXIT DOOR DOES NOT CLOSE PROPERLY. READJUSTED LT EMERGENCY EXIT DOOR. (K)

GLB2008F00020

BEECH

 

 

FRAME

CRACKED

9/2/2008

1900D

 

 

 

FS 177 S9AR

DURING STRUCTURAL INSP MAINT FOUND FRAME CRACKED AT STRINGER CUTOUT FS 177.3 AT STRINGER 9AR. LENGTH OF CRACK APPROXIMATELY .750. (K)

GUU2008F00047

BEECH

 

 

CABLE

BROKEN

8/26/2008

1900D

 

 

12951405933

PAX DOOR

PILOT REPORTED UNABLE TO OPEN CABIN DOOR, FOUND UPPER FWD DOOR CABLE BROKEN. REPLACED UPPER FWD DOOR CABLE. (K)

GLB2008F00024

BEECH

 

 

FRAME

CRACKED

9/2/2008

1900D

 

 

 

FS 177.3 S9AR

DURING STRUCTURAL INSPECTION MAINTENANCE FOUND FRAME CRACKED AT STRINGER CUTOUT FS 177.3 AT STRINGER 9AR. LENGTH OF CRACK APPROXIMATELY .750". MAINTENANCE REPAIRED FRAME CRACK AT STRINGER RELIEF HOLE IAW SRM 51-70 AT FS 177.3 AT STRINGER 9AR. REPAIR APPROXIMATELY 5 INCH BY 2.5". 2024-T3. RII INSPECTION COMPLIED IAW TASKCARD 8.2.1. (K)

GLB2008F00026

BEECH

 

 

STIFFENER

CRACKED

9/3/2008

1900D

 

 

 

RT MLG WW KEEL

DURING STRUCTURAL CHECK MAINT DISCOVERED A CRACK ON THE RT WHEEL WELL OB KEEL TAB TO OB FENDER STIFFENER 1" AT THE BOTTOM END OF STIFFENERS TO KEEL AREA. " SUPPLEMENTAL INFORMATION WILL BE PROVIDED UPON COMPLETION OF THE REPAIR". (K)

GUU2008F00045

BEECH

 

 

CABLE

BROKEN

8/26/2008

1900D

 

 

12951405933

PAX DOOR

PILOT REPORTED UNABLE TO OPEN CABIN DOOR, FOUND UPPER FWD DOOR CABLE BROKEN. REPLACED UPPER FWD DOOR CABLE. (K)

GUU2008F00065

BEECH

 

 

WIRE

OUT OF POSITION

9/14/2008

1900D

 

 

 

LANDING LIGHT

AFTER TAKEOFF UPON TURNING BOTH LANDING LIGHTS SWITCHES OFF THERE WAS A SPARK COMING OUT OF THE SWITCH. SPLICED AND REPOSITIONED WIRE AT LT LANDING LIGHT SWITCH. OPS CHECK GOOD. (K)

GLB2008F00023

BEECH

PWA

 

B-NUT

LOOSE

9/4/2008

1900D

PT6A67D

 

 

FUEL LINE

PILOTS REPORTED IN CRUISE AND DESCENT A STRONG FUEL ODOR IN THE COCKPIT AND CABIN AREA. MAINTENANCE TIGHTENED A LOOSE "B" NUT IN THE FUEL PURGE AREA ON THE NR (1) ENGINE IAW MM 28-20. CLEANED CHECK VALVES ON THE FUEL PURGE SYSTEMS FOR THE RT ENGINE AND LT ENGINE IAW MM 71-70. NO NEW ODORS WERE PRESENT. (K)

2008FA0000703

BEECH

 

 

BOLT

OUT OF ADJUST

10/2/2008

200BEECH

 

 

NAS428420

ELEVATOR CONTROL

DURING A PHASE 1-4 INSPECTION ON AC. BOLT FOR ELEVATOR CONTROL SYS. WAS FOUND TO BE ADJUSTED ALL THE WAY DOWN AND WAS NOT PROVIDING A STOP FOR THE BALLAST. IN THIS CONDITION, THE POSSIBILITY EXISTS FOR THE INTERCONNECT LINK BETWEEN THE BALLAST WEIGHT BELLCRANK AND THE CONTROL COLUMN BRACKET TO TRAVEL PAST AN OVERCENTER CONFIGURATION AND MAY PREVENT PROPER CONTROL OF THE ELEVATOR SYSTEM IF THE ELEVATOR PRIMARY OR SECONDARY STOPS FAIL OR ARE ADJUSTED INCORRECTLY. THE PHASE INSPECTION BEING CONDUCTED IS THE INITIAL INSPECTION ON THE AC, AND LOG RESEARCH DID NOT REVEAL ANY PRIOR MAINTENANCE ON THE ELEVATOR CONTROL SYSTEM RIGGING. (K)

2008FA0000590

BEECH

PWA

 

STRUT

MALFUNCTIONED

8/13/2008

300BEECH

PT6A60A

 

998201005

NLG

POSITION OF THIS TORQUE LINK MOUNT RELATIVE TO THE SHIMMY DAMPNER ARMS HOLE ARE SUCH THAT THE TWO PARTS INTERFERE WITH EACH OTHER AND DON’T ALLOW THE STRUT TO COMPRESS CLOSER THAN 2 INCHES FROM FULLY COLLAPSED. (K)

 

 

RU32008F00000

BEECH

PWA

 

ENGINE

FAILED

8/14/2008

300BEECH

PT6A60A

 

 

LEFT

CLIMBING THRU 7300`, AT CLIMB POWER, HEARD A PRONOUNCED POP, FELT THE ACFT YAW LT AND FELT A DECELERATION. THE PILOT FLYING CONFIRMED THAT THE LT ENGINE HAD SHUTDOWN AND THE PROP HAD FEATHERED. ATC WAS NOTIFIED AND EMERGENCY WAS DECLARED. THE ENGINE FAILURE IN FLIGHT EMERGENCY CHECKLIST WAS COMPLETED AS WELL AS THE SINGLE ENGINE LANDING CHECKLIST. AFTER AN UNEVENTFUL LANDING AND TAXI OFF OF THE RUNWAY, THE SHUTDOWN CHECKLIST WAS ACCOMPLISHED AND THE ACFT WAS TOWED TO THE HANGER. (K)

2008FA0000619

BEECH

PWA

 

CONTACT

ERODED

9/15/2008

300BEECH

PT6A60A

 

 

RELAY

HAD 3 FAILURES OF THE SAME RELAY, FIRST RELAY LASTED 457 HOURS, SECOND RELAY LASTED 187 HOURS, AND THE THIRD RELAY LASTED 415 HOURS. MOST OF THE TIME THE FAILURE STARTS WITH THE 2 MICRO SWITCHES IN THE COVER GOING BAD. FOR HAVING RELATIVELY LOW TIME, THE MAIN CONTACTS WERE ERODED FAIRLY WELL. (K)

2008FA0000714

BEECH

CONT

 

V-BELT

DEPARTED

10/9/2004

35C33

O470N

 

53954732

ALTERNATOR

PILOT REPORTED LOSS OF ELECTRICAL POWER IN CRUISE FLIGHT DURING NIGHT VFR. V-BELT OBSERVED MISSING FROM ACCESSORY CASE ABSENT FROM ALTERNATOR PULLEY. V-BELT APPARENTLY LOST IN FLIGHT THROUGH OPENING IN LOWER COWLING. OWNER REPORTS THAT ONLY 25-30 HOURS WAS PUT ON THIS COMPONENT. (K)

DXTA200803271

BEECH

 

 

BRAKE ASSY

WEAK

9/10/2008

400A

 

 

 

MLG

BRAKING IS MUSHY DURING TAXI. (K)

DXTA200803270

BEECH

 

 

WARNING LIGHT

ILLUMINATED

9/10/2008

400A

 

 

 

RUDDER

ON TAKEOFF ROLL BELOW 80 KTS AT TAKEOFF POWER, RUDDER BOOST FAIL ANNUNCIATOR LIGHT COMES ON. ABORTED TAKEOFF. (K)

2008FA0000650

BEECH

 

 

BRACKET

CRACKED

9/5/2008

400A

 

 

45A336065

FUSELAGE

DURING SCHEDULED AIRFRAME INSPECTION FOUND PN 45A33606-5 AND PN 45A33606-6 CABIN UNDER FLOOR REINFORCING BRACKETS AT CABIN DOOR ENTRANCEWAY CRACKED. SEE SRM 53-10-50-001, FIG 1, SHEET 2 OR 3, ITEMS 29 AND 30. SUSPECT CRACKED FROM FATIGUE, ALSO POSSIBLY FROM PREVIOUS ROUGH CABIN DOOR STEP ASSY HANDLING. AC TECHNICIANS/ INSPECTORS SHOULD INSPECT THIS AREA CAREFULLY DURING SCHEDULED INSPECTIONS ON HIGHER TIME AIRCRAFT, AND/OR AIRCRAFT WITH PREVIOUS HISTORY OPERATED BY CHARTER/AIR TAXI/ FRACTIONAL OPERATORS. (K)

DJF2008F00014

BEECH

PWA

 

ENGINE

MAKING METAL

9/9/2008

400A

JT15D5

 

 

 

REPORTED LOW OIL PRESSURE IN FLIGHT. THE AFFECTED ENGINE WAS SHUTDOWN, AN EMERGENCY WAS DECLARED AND THE AIRCRAFT DIVERTED. MAINTENANCE FOUND METAL IN THE OIL SYSTEM. THE ENGINE WAS REMOVED FOR OEM EVALUATION. AIRCRAFT RETURNED TO SERVICE. (K)

2008FA0000631

BEECH

 

WOODWARD

ROD

BROKEN

9/11/2008

58

 

 

210044

GOVERNOR

LIFT ROD WAS DISCOVERED BROKEN AT DISASSEMBLY. (K)

2008FA0000693

BEECH

CONT

 

ROD

BROKEN

9/11/2008

58

IO520C

 

210044

GOVERNOR

LIFT ROD WAS DISCOVERED BROKEN AT DISASSEMBLY. (K)

2008FA0000628

BEECH

LYC

 

HINGE BRACKET

CORRODED

7/22/2008

76

O360*

 

10516000015

LT WING TE FLAP

LT FLAP OB HINGE BRACKET, SEVERE CORROSION AT IB AND OB SUPPORT RIBS, WHERE HINGE BRACKET PIN FLAP. UNABLE TO PERFORM VISUAL INSPECTION OF AREA AS DAMAGE IS CONCEALED INSIDE OF SKIN. (K)

2008FA0000627

BEECH

LYC

 

HINGE BRACKET

CORRODED

7/23/2008

76

O360*

 

710516000015

LT WING TE FLAP

LT FLAP OB HINGE BRACKET, SEVERE CORROSION AT IB AND OB SUPPORTING RIBS WHERE HINGE BRACKET JOINS FLAP. UNABLE TO PERFORM VISUAL INSPECTION OF AREA AS DAMAGE IS CONCEALED BY SKIN. (K)

2008FA0000630

BEECH

LYC

BEECH

HINGE BRACKET

CORRODED

7/23/2008

76

O360*

 

10516000015

LT WING TE FLAP

LT FLAP OB HINGE BRACKET, SEVERE CORROSION AT IB AND OB SUPPORTING RIBS WHERE HINGE BRACKET JOINS FLAP. UNABLE TO PERFORM VISUAL INSPECTION OF AREA AS DAMAGE IS CONCEALED BY SKIN. (K)

2008FA0000629

BEECH

LYC

BEECH

HINGE BRACKET

CORRODED

7/22/2008

76

O360*

 

10516000015

LT WING TE FLAP

LT FLAP OB HINGE BRACKET, SEVERE CORROSION AT IB AND OB SUPPORTING RIBS WHERE HINGE BRACKET JOINS FLAP. UNABLE TO PERFORM VISUAL INSPECTION OF AREA AS DAMAGE IS CONCEALED BY SKIN. (K)

EGQ2008F00000

BEECH

GARRTT

 

DETECTION SYS

MALFUNCTIONED

9/14/2008

B100

TPE331*

 

 

RT FIRE DETECT

APPROX 1 MINUTE AFTER DEPARTURE, RT ENGINE FIRE LIGHT CAME ON STEADY FOR ABOUT 30 SECONDS THEN OFF, ABOUT 30 SECONDS LATER RT ENGINE FIRE LIGHT CAME ON AGAIN FOR 30 SECONDS THEN OFF. CREW FOLLOWED FIRE DETERMINATION PROCEDURES AND DETERMINED THERE WAS NO FIRE AND RETURNED TO DEPARTURE AIRPORT. ALL UNEVENTFUL. THE CAUSE OF THE INDICATION INVESTIGATED. A FULL ENGINE COMPARTMENT INSPECTION PERFORMED WITH NO INDICATIONS OF SMOKE OR FIRE. ENGINE FIRE DETECTION SYSTEM TEST PERFORMED, ALL OPERATION NORMAL. ENGINE FIRE SENSORS WERE TESTED INDIVIDUALLY AND ALL OPERATED NORMALLY. ACFT RETURNED TO SERVICE WITH NO FURTHER OCCURRENCES FOR THE ENGINE FIRE LIGHT. (K)

2008FA0000699

BEECH

PWA

 

STRINGER

CRACKED

10/10/2008

C90

PT6*

 

50440012319

FS 298

REAR PRESSURE BULKHEAD, FS 298.00, ON RT SIDE. STRINGER NR 9 WAS FOUND CRACKED ON THE AFT SIDE OF THE REAR PRESSURE BULKHEAD AT THE POINT WHERE THE ZEE STIFFENER IS ATTACHED TO THE STRINGER WITH (6) RIVETS. (K)

 

 

2008FA0000617

BEECH

PWA

 

BLOWER

FAILED

8/22/2008

C90A

PT6A21

 

903840311

VENT

PILOT DETECTED SMOKE IN CABIN, LANDED. TROUBLESHOT ODOR, CHECK IN ENGINE BAYS, NO DEFECT NOTED. FOUND CABIN VENT BLOWER NOT WORKING, CHECKED BLOWER SYSTEM WIRING, NO DEFECTS NOTED, CHECKED VENT BLOWER UNDER PILOT FLOOR AND FOUND BLOWER MOTOR LOCKED UP. REMOVED ASSY FOUND MOTOR HAD BURNED, ELEC ODOR. REMOVED AND REPLACED VENT BLOWER WITH OVERHAULED UNIT. OPERATION CHECKED NORMAL. THIS MOTOR RUNS ON LOW SPEED ANYTIME AUTO COOL OR AUTO HEAT SWITCH IS ON OR WITH BLOWER SWITCH IN LOW OR HIGH AND ENGINES ARE RUNNING. DURING INSPECTION WITH THIS LOCATION OPEN, CHECK BLOWER FOR PROPER OPERATION AND SPEED. (K)

2008FA0000613

BEECH

PWA

 

CLAMP

FAILED

9/3/2008

F90

PT6A60A

 

C13019S

BLADE

PROPELLER UNIT WAS OVERHAULED ON JULY 28, 2008, WO 79785. THE PROPELLER WAS INSTALLED ON ACFT AUG 27, 2008. UPON RUN UP OF ACFT, THE MECHANIC NOTED A GREASE LEAK FROM THE PROPELLER BLADE. A CRACK WAS FOUND. O/H FACILITY WAS NOTIFIED OF THE FINDINGS. THE PROPELLER WAS REMOVED FROM THE ACFT AND RETURNED TO THE FACILITY FOR INSPECTION . O/H FACILITY VERIFIED THE SAME FINDINGS. BLADE CLAMP WAS REMOVED AND REPLACED WITH AN OHC CLAMP ASSY. ALL WORK WAS PERFORMED IAW SRM 118F, 202A, AND 133C. (K)

2008FA0000660

BEECH

CONT

 

CONTACT

FAILED

9/17/2008

G35

E2258

 

10357174

RT MAGNETO

RT MAGNETO FAILED COMPLETELY IN FLIGHT DUE TO THE TIP OF THE CONTACT POINTS HAVING SEPARATED FROM HE ASSY. THIS LEFT THE CONTACTS AND THEREFORE PRIMARY ELECTRICAL CIRCUIT IN A CONTINUALLY OPEN POSITION. RENDERING THE MAGNETO INOPERATIVE. IN A PHONE CONVERSATION WITH THE MFG REP, MFG IS AWARE OF THE POTENTIAL CONDITION AND HAD ISSUED A DISTRIBUTOR INFORMATION BULLETIN D1B2008-3. RECALLING CONTACT ASSY AT THE DISTRIBUTOR LEVEL MFG WITH DATE CODES OF 0716-0816 OR THE (16) WEEK OF 2007 TO THE (16) WEEK OF 2008. THE CONTACTS THAT WERE INSTALLED IN THIS MAGNETO IN MAY OF2008 DURING A ROUTINE 500 HR INSP, HAD APPARENTLY MADE THEIR WAY INTO THE RETAIL INVENTORY SYS. (K)

2008FA0000633

BELL

 

 

SERVO

MALFUNCTIONED

8/26/2008

206B3

 

 

206076031107

RT CYCLIC

DURING START, PILOT NOTICED CYCLIC STICK COULD NOT BE MOVED WHEN THE HYD OFF PROTAKE OFF CHECK WAS INITIATED. WITH HYD POWER ON, FLT CONTROL OP NORM. THE HELICOPTER RETURNED FROM FLT, THE HYDRAULIC FIELD AND SERVO WERE HOT, IT WAS A VERY HOT DAY, TEMP ABOUT 96 DEGREES. PILOT NOTICED THE CYCLIC STICK COULD NOT BE MOVED DURING HIS HYD CHECK. IT WAS SHUT DOWN AND BROUGHT INTO THE HANGAR MX. A HYD MULE WAS HOOKED UP AND OPS NORMAL. BELL HELICOPTER TECH REP WAS NOTIFIED AND ASKED TO COME TO THE FACILITY. THE TECHS DID A GROUND RUN FOR APPROX 15 MIN W/O INCIDENT. AFTER HOVERING FOR 5 MINUTES, THE PROBLEM RETURNED. THE PROB APPEARED TO BE THE RT HYD SERVO (S/N 8528). LT SERVO WAS NEAR OVERHAUL, WE REPLACED IT AS WELL AS THE SUSPECTED PROB SERVO. AFTER REPLACEMENT, THE PROB DID NOT REOCCUR. BOTH SERVOS WERE SENT TO BHT FOR EVAL. WE ASKED FOR A DETAILED REPORT. AS OF THIS REPORT, NO INFORMATION HAS BEEN RECEIVED.

2008FA0000609

BELL

ALLSN

 

BLADE

FAILED

9/5/2008

206B3

250C20J

 

 

COMPRESSOR

THIRD STAGE COMPRESSOR BLADE, ONE OF THE BLADES WAS "THROWN" FROM THE PART. NOTE: THIS COMPRESSOR WHEEL IS A ONE-PIECE BLADE DISK. (K)

2008FA0000608

BELL

ALLSN

HONEYWELL

BEARING

FAILED

9/4/2008

206L1

250C30

 

2544198

PT GOVERNOR

SPOOL BEARING ASSY (PN 2544198) FAILED INTERNALLY. BEARING ASSY NO LONGER ROTATES AND CAUSED DRIVE SHAFT (PN 2539033) GUIDE POST AND FORK ON GOVERNOR LEVER ASSY. (PN 2523293) TO BEND. ONE FLYWEIGHT (PN 2544200) WAS DAMAGED FROM THE SPOOL BEARING CHAFING. (K)

HEF2008F00000

BELL

ALLSN

 

BEARING

FAILED

9/3/2008

206L4

250C30

 

2544198

SPOOL

UPPER BEARING, (PN 2525465) INSIDE OF SPOOL BEARING ASSY FAILED (CAME APART). LOWER SPOOL BEARING, (PN 2525468) IS STILL INTACT, BUT NO LONGER ROTATES FREELY. (K)

2008FA0000610

BELL

ALLSN

 

BEARING

FAILED

9/8/2008

206L4

250C30

 

2544198

SPOOL

SPOOL BEARING ASSY FAILED INTERNALLY. BEARING ASSY NO LONGER ROTATES AND CAUSED DRIVE SHAFT GUIDE POST AND FORK IN GOVERNOR LEVER ASSY TO BEND. THE UPPER BEARING LOWER SHIELD AND RETAINER HAS COME OFF. THE LOWER BEARING IS INTACT BUT NO LONGER ROTATES. (K)

QML2008F00012

BELL

 

 

PANEL

LEAKING

9/11/2008

407

 

 

 

FUSELAGE

ON SHORT FINAL ABORT, SMOKE, SPARKS, BRIGHTER THAN NORMAL OVERHEAD LIGHTING AND A STRONG ODOR CAME FROM THE OVERHEAD PANEL. ON TOUCHDOWN THE INSTRUMENT PANEL LIGHTS RHEOSTAT SWITCH ADJUSTED TO OFF POSITION - SMOKE, SPARKS, AND BRIGHTER THAN NORMAL LIGHTING STOPPED IMMEDIATELY. WATER DRIPPING FROM THE OVERHEAD PANEL. NORMAL SHUTDOWN COMPLETED. MAINT CALLED. MAINT COMMENT- RAINWATER ENTERED WHERE AN ANTENNA COAX PASSES THRU THE DECK, AND RAN DOWN A TRIM PANEL TO THE CIRCUIT BREAKER PANEL. THE LIGHTED PANEL IS ATTACHED TO THE LOWER SIDE OF THE CIRCUIT BREAKER PANEL AND WATER COLLECTED ON TO AND ENTERED THE LIGHTED PANEL. THIS PANEL IS MODIFIED FOR NVG LIGHTING. NOTE: THIS IS THE SECOND OR POSSIBLY THE THIRD PANEL THE MECHANIC HAVE SEEN SHORTED OUT IN THIS MANNER. (K)

2008FA0000646

BELL

 

 

BLADE

CRACKED

9/1/2008

407

 

 

407015001111

MAIN ROTOR

M/R BLADE HAS 2706.0 HRS TT WHEN CLEANING BLADE FOR REINSTALLATION, MANY SHALLOW CRACKS WERE FOUND ON THE TOP SURFACE OF BLADE 24 INCH IB OF TRIM TAB. THE CRACKS RUN 45 DEGREES TO BLADE SPAN. CONTACTED MFG PRODUCT SUPPORT AND WAS INFORMED THAT THIS CONDITION IS CALLED "TRACER STRANDS" AND IS A CONDITION NEEDING REPAIR. PRODUCT SUPPORT ALSO INFORMED US THAT THIS WOULD BE REFERENCED INT THE MANUALS IN THE NEAR FUTURE AND THAT NEWER BLADES HAVE BEEN CORRECTED FOR THIS PROBLEM. (K)

MWE2008F00039

BOEING

 

 

DOUBLER

CORRODED

8/27/2008

717200

 

 

594115853

BS 994 L28R

AFT CARGO BAY STAR DOUBLER AT STA 994 LONGERON 28R IS EXFOLIATED AROUND SCREW HOLE. REMOVED AND REPLACED STAR DOUBLER.

MWE2008F00042

BOEING

 

 

SLIDE

UNWANTED DEPLOY

9/24/2008

717200

 

 

D29982225

GALLEY AREA

FWD SERVICE DOOR EMERGENCY SLIDE IN UNARMED POSITION FROM BEING SECURED IN DOOR/COVER BRACKETS. FOUND EMERGENCY SLIDE DEPLOYED. REMOVED AND REPLACED EMERGENCY SLIDE. (K)

MWE2008F00040

BOEING

 

 

SMOKE DETECTOR

FAILED

9/5/2008

717200

 

 

CBAB110001

LT LAV

LT LAVATORY SMOKE DETECTOR TEST FAILED. REMOVED AND REPLACED SMOKE DETECTOR. (K)

MWE2008F00041

BOEING

 

 

SMOKE DETECTOR

FAILED

9/8/2008

717200

 

 

CBAB110001

LT LAVATORY

LT LAVATORY SMOKE DETECTOR DID NOT WORK DURING FUNCTION TEST. REMOVED AND REPLACED SMOKE DETECTOR. (K)

MWE2008F00036

BOEING

 

 

BATTERY PACK

INOPERATIVE

8/30/2008

717200

 

 

6011779

EMERGENCY LIGHT

BOTH LT AND RT EXTERIOR EMERGENCY LIGHTS ARE INOPERATIVE. REMOVED AND REPLACED OVERWING EMERGENCY BATTERY PACK. (K)

 

 

MWE2008F00034

BOEING

RROYCE

 

LAMP

BURNED OUT

8/30/2008

717200

BR700715A130

 

316

EMERGENCY LIGHTS

EMERGENCY LIGHT AFT CEILING AREA IN AFT ACCESSORY IS INOPERATIVE. RELAMPED. (K)

DHL2008F00045

BOEING

 

 

LIGHT

INOPERATIVE

9/26/2008

727200

 

 

1000677

CABIN

COCKPIT EMERGENCY EXIT LIGHT INOP. REMOVED AND REPLACED EMERGENCY EXIT LIGHT ASSEMBLY IAW MM 33-50-93. OP CHECK GOOD. ACFT GROUNDED. (K)

G8G2008F00000

BOEING

 

 

ACCESSORY UNIT

MALFUNCTIONED

5/28/2008

727200

 

 

6560214106

INSTRUMENT PANEL

DURING CRUISE OPERATION CAPTAIN’S RMI CARD AND FO`S HSI CARD STOPPED TURNING IN FLIGHT, BOTH RMI NEEDLES FROZE IN POSITION. AC RETURNED TO DEPARTURE WHERE IT LANDED WITHOUT INCIDENT. POST FLIGHT INSPECTION REVEALED THE FLIGHT INSTRUMENT ACCY UNIT AT FAULT. REMOVED AND REPLACED FLIGHT INSTRUMENT ACCY UNIT, OPS CHECK GOOD. NO OTHER DEFECTS WERE NOTED. AIRCRAFT WAS RETURNED TO SERVICE. (K)

C8G2008F00014

BOEING

 

 

ACM

INOPERATIVE

5/29/2008

727223

 

 

2040751

LEFT

DURING CLIMB OPERATION, THE AC WAS UNABLE TO MAINTAIN CABIN ALTITUDE BELOW 10000 FEET WITH ONE PACK OPERATION. AC RETURNED TO DEPARTURE, WHERE IT LANDED WITHOUT INCIDENT. POST FLIGHT INSP REVEALED LT ACM INOPERATIVE. REMOVED AND REPLACED LT ACM AND LT PACK SHUTOFF VALVE, OPS CHECK GOOD. NO OTHER DEFECTS NOTED. AC WAS RETURNED TO SERVICE

G8G2008F00001

BOEING

 

 

FITTING

FAULTY

6/11/2008

727223

 

 

439563

BYPASS SWITCH

DURING CLIMB, THE NR 2 ENGINE LOW OIL PSI LIGHT ILLUMINATED AND OIL QUANTITY WENT TO EMPTY. THE NR 2 ENGINE WAS SHUT DOWN, AN EMERGENCY WAS DECLARED AND THE AIRCRAFT LANDED WITHOUT INCIDENT. POST FLIGHT INSPECTION FOUND OIL FILTER BYPASS SWITCH GEARBOX FITTING AT FAULT. REPAIRED GEARBOX PERFORMED OPS AND LEAK CHECKS GOOD. NO OTHER DEFECTS. AIRCRAFT WAS RETURNED TO SERVICE. (K)

DHL2008F00034

BOEING

 

 

FRAME

DENTED

9/17/2008

727224

 

 

 

FUSELAGE

UPPER FUSELAGE PAX CABIN AT BS 500 BETWEEN STRINGER 16R AND 17R FRAME WITH DENT. REPAIRED FUSELAGE FRAME SECTION AT BS 500 BETWEEN STRINGER 16R AND STRINGER 17R DUE TO DENT IAW SRM 51-40-3, FIG 1. (K)

DHL2008F00042

BOEING

 

 

FRAME

DAMAGED

9/24/2008

727224

 

 

 

FUSELAGE

UPPER FUSELAGE PAX CABIN AT BS 720D BETWEEN STRINGER 13L AND 14L FRAME WITH DOUBLE HOLES. REPAIRED UPPER FUSELAGE BODY FRAME SECTION AT BS 720D BETWEEN STRINGER 11 AND 14 LEFT SIDE DUE TO DOUBLE HOLES IAW SRM 53-10-4, FIG 1, DETAIL 1. (K)

DHL2008F00035

BOEING

 

 

FRAME

DENTED

9/12/2008

727224

 

 

 

FUSELAGE

UPPER FUSELAGE PAX CABIN AT BS 700 BETWEEN STRINGER 16R AND 17R FRAME WITH DENT. REPAIRED FUSELAGE FRAME SECTION AT BS 700 BETWEEN STRINGER 16 AND 17 RT SIDE DUE TO DENT IAW SRM 51-40-3, FIG 1. (K)

DHL2008F00036

BOEING

 

 

FRAME

DAMAGED

9/16/2008

727224

 

 

 

FUSELAGE

UPPER FUSELAGE PAX CABIN AT BS 720B STRINGER 13L AND 14L FRAME WITH DOUBLE HOLES. REPAIRED FUSELAGE FRAME SECTION AT BS 720B BETWEEN STRINGER 11 AND 14 LEFT SIDE DUE TO DOUBLE HOLES IAW SRM 53-10-4, FIG 1 DETAIL 1. (K)

DHL2008F00037

BOEING

 

 

FRAME

DENTED

9/17/2008

727224

 

 

 

FUSELAGE

UPPER FUSELAGE PAX CABIN AT BS 660 BETWEEN STRINGER 16R AND 17R FRAME WITH DENT. REPAIRED FUSELAGE FRAME SECTION AT BS 660 BETWEEN STRINGER 16 AND 17 RT SIDE DUE TO DENT IAW SRM 51-40-3, FIG 1. (K)

DHL2008F00038

BOEING

 

 

FRAME

DAMAGED

9/12/2008

727224

 

 

 

FUSELAGE

UPPER FUSELAGE PAX CABIN AT BS 720B STRINGER 8R FRAME WITH DOUBLE HOLES. REPAIRED FUSELAGE FRAME SECTION AT BS 720B BETWEEN STRINGER 7 AND 9, RT SIDE, DUE TO DOUBLE HOLES IAW SRM 53-10-4. (K)

DHL2008F00040

BOEING

 

 

FRAME

DENTED

9/13/2008

727224

 

 

 

FUSELAGE

UPPER FUSELAGE PAX CABIN AT BS 460 BETWEEN STRINGER 16R AND 17R FRAME WITH DENT. REPAIRED FUSELAGE FRAME SECTION AT BS 460 BETWEEN STRINGER 16 AND 17 RT SIDE, DUE TO DENT IAW SRM 51-40-3, FIG 1. (K)

DHL2008F00041

BOEING

 

 

FRAME

DENTED

9/12/2008

727224

 

 

 

FUSELAGE

UPPER FUSELAGE PAX CABIN AT BS 680 BETWEEN STRINGER 16R AND 17R FRAME WITH DENT. REPAIRED FUSELAGE FRAME SECTION AT BS 680 BETWEEN STRINGER 16 AND 17 RIGHT SIDE, DUE TO DENT IAW SRM 51-40-3, FIG 1. (K)

DHL2008F00039

BOEING

 

 

FRAME

DAMAGED

9/12/2008

727224

 

 

 

FUSELAGE

UPPER FUSELAGE PAX CABIN AT BS 720C STRINGER 8R FRAME WITH DOUBLE HOLES. REPAIRED FUSELAGE FRAME SECTION AT BS 720C BETWEEN STRINGER 7 AND 9 RT SIDE, DUE TO DOUBLE HOLES IAW SRM 53-10-4, FIG 2. (K)

DHL2008F00043

BOEING

 

 

SKIN

DAMAGED

9/18/2008

727224

 

 

 

CARGO DOOR

LOWER FUSELAGE AFT CARGO COMPARTMENT DOOR NR 2 OUTER SKIN WITH DOUBLE HOLES AT BS 950F + 8 BETWEEN UPPER FRAME AND BEAM NR 1. REPAIRED LOWER FUSELAGE AFT CARGO COMPARTMENT DOOR NUMBER 2 OUTER SKIN SECTION FROM BS 950F+3.5 TO BS 950F + 10.5 BETWEEN UPPER FRAME AND BEAM NUMBER 1 DUE TO SKIN WITH DOUBLE HOLES IAW SRM 52-00-3, FIG 4. (K)

 

 

DHL2008F00044

BOEING

 

 

FRAME

DAMAGED

9/24/2008

727224

 

 

 

FUSELAGE

UPPER FUSELAGE CARGO CABIN, FRAME WITH DOUBLE HOLE AT BS 1070 BETWEEN STRINGER 5L AND 6L. REPAIRED UPPER FUSELAGE BODY FUSELAGE BODY FRAME SECTION AT BS 1070 BETWEEN STRINGER 4 AND 6 LEFT SIDE DUE TO DOUBLE HOLES IAW SRM 53-10-4, FIG 1. (K)

C8G2008F00017

BOEING

 

 

FCU

UNSERVICEABLE

9/3/2008

727225

 

 

74360205

NR 1 ENGINE

SHORTLY AFTER TAKEOFF DURING CLIMB OPERATION THE NR 1 ENGINE SPREAD 28 HIGH AND ALL ENGINE INDICATORS BEGAN TO DECREASE INDICATING A FAILURE. THE ENGINE THEN RELIT DUE TO CONTINUOUS IGNITION BEING ENGAGED. 2 OR 3 MINUTES LATER THE SAME EVENT OCCURRED. THE AC RETURNED TO ELP WHERE IT LANDED WITHOUT INCIDENT. POST FLIGHT INSPECTION WAS PERFORMED. THE NR 1 FUEL CONTROL UNIT, ENGINE DRIVEN FUEL PUMP AND THE P&D VALVE WERE REMOVED AND REPLACED, OPS CHECKS GOOD. NO OTHER DEFECTS WERE NOTED. AC WAS RETURNED TO SERVICE. (K)

C8G2008F00015

BOEING

 

 

INDICATOR

INOPERATIVE

8/23/2008

727225

 

 

20412151101

WX RADAR

AFTER TAKEOFF FOUND RADAR UNSUITABLE FOR FLIGHT OPERATIONS INTO KNOWN CONVECTIVE ACTIVITY. ON ROTATION WX RADAR DOES NOT STABILIZE REGARDLESS OF PITCH KNOB SELECTION, RADAR SHOWS COMPLETELY COVERS SCREEN. DURING CRUISE RADAR INDICATES FALSE TARGETS ON ALL PITCH SETTINGS. AC RETURNED TO DEPARTURE WHERE IT LANDED WITHOUT INCIDENT. POST FLIGHT INSP WAS PERFORMED. REMOVED AND REPLACED NR 2 VERTICAL GYRO, RADAR ANTENNA AND RADAR INDICATOR. OPS CHECKS WERE SATISFACTORY. AC WAS RETURNED TO SERVICE. NO OTHER DEFECTS WERE NOTED. (K)

C8G2008F00010

BOEING

 

 

ANTENNA

INOPERATIVE

7/22/2008

727225

 

 

20675680501

WX RADAR SYSTEM

FLT 1204, AFTER TAKEOFF, THE RADAR WAS SPOOKING AND WOULD NOT PAINT KNOWN BAD WEATHER . THE AIRCRAFT RETURNED, WHERE IT LANDED WITHOUT INCIDENT. POST FLIGHT INSP REVEALED THE RADAR ANTENNA AT FAULT. REMOVED AND REPLACED RADAR ANTENNA PERFORMED OPERATIONAL CHECKS GOOD. NO OTHER DEFECTS WERE NOTED. AIRCRAFT WAS RETURNED TO SERVICE. (K)

C8G2008F00012

BOEING

 

 

SMOKE DETECTOR

INOPERATIVE

7/17/2008

727225

 

 

77401

CARGO BAY

DURING CLIMB OUT OPERATION, THE MAIN DECK FIRE WARNING LIGHT ILLUMINATED. THE AIRCRAFT RETURNED TO DEPARTURE WHERE IT LANDED WITHOUT INCIDENT. POST FLIGHT INSPECTION REVEALED THAT THE LT WARNING LIGHT ILLUMINATED STEADY. VERIFIED THAT NO SMOKE OR FIRE WAS PRESENT. LIGHT EXTINGUISHED AFTER RESEATING THE NR 8 SMOKE DETECTOR. REMOVED AND REPLACED THE NR 8 SMOKE DETECTOR AS PRECAUTION REMOVED AND REPLACED THE NR2, NR 4, NR 6, NR 10, NR 12 ON THE LT SIDE AND NR 9 ON THE RT. ALL OPERATIONAL CHECKS GOOD. NO OTHER DEFECTS WERE NOTED AIRCRAFT WAS RETURNED TO SERVICE. (K)

C8G2008F00013

BOEING

PWA

 

INDICATOR

FAULTY

6/11/2008

727225

JT8D15

 

152BL801E

EGT

DURING TAKEOFF ROLL THE NR 2 ENGINE EGT INDICATOR WENT TO ZERO INDICATION. THE TAKEOFF WAS ABORTED, WHERE THE AC RETURNED TO BLOCKS WITHOUT INCIDENT. POST FLIGHT INSPECTION REVEALED NR 2 ENGINE EGT INDICATOR AT FAULT. THE NR 2 ENGINE EGT INDICATOR WAS REMOVED AND REPLACED. OPS GOOD. NO OTHER DEFECTS WERE NOTED. AIRCRAFT WAS RETURNED TO SERVICE. (K)

C8G2008F00018

BOEING

PWA

 

TURBINE

DAMAGED

9/10/2008

727225

JT8D15

 

 

NR 2 ENGINE

ON TAKEOFF, JUST AFTER V2 THE NR 2 ENGINE FAILED. AN EMERGENCY WAS DECLARED AND THE ACFT RETURNED, WHERE IT LANDED WITHOUT INCIDENT. POST FLIGHT INSP REVEALED TURBINE DAMAGE. THE NR 2 ENGINE WAS REMOVED AND REPLACED. OPS CHECK GOOD. NO OTHER DEFECTS WERE NOTED, ACFT WAS RETURNED TO SERVICE. (K)

C8G2008F00016

BOEING

 

 

LINE

LEAKING

8/26/2008

727227

 

 

 

ENGINE FUEL

ON ROTATION THE NR 3 ENGINE FAILED. THE CREW PERFORMED APPROPRIATE CHECKLIST. AN EMERGENCY WAS DECLARED AND THE AC RETURNED WHERE IT LANDED WITHOUT INCIDENT. POST FLIGHT INSP WAS PERFORMED, IT WAS NOTED THAT THE FUEL FEED LINE TO THE P & D VALVE WAS LEAKING. THE PACKING WAS REPLACED AND THE LINE SECURED. OPERATIONAL AND LEAK CHECKS WERE PERFORMED SATISFACTORILY. NO OTHER DEFECTS WERE NOTED. AC WAS RETURNED TO SERVICE. (K)

C8G2008F00009

BOEING

 

 

CONNECTOR

DIRTY

8/5/2008

727227

 

 

 

NR 8 SLAT

AFTER TAKEOFF, DURING CLIMB, OPERATION, THE NR 8 SLAT WOULD NOT RETRACT. POST FLIGHT INSP WAS PERFORMED AND THE NR 8 SLAT ACTUATOR CONNECTOR WAS CLEANED AND SYSTEM WAS OPERATIONAL CHECKED WITH NO DEFECTS. NO OTHER DEFECTS WERE NOTED. AC WAS RETURNED TO SERVICE. (K)

RYN2008F00024

BOEING

 

 

STRUCTURE

CORRODED

10/1/2008

727232

 

 

 

EMERGENCY EXIT

LT HARD AFT OVERWING ESCAPE HATCH CUTOUT LOWER SECTION HAVE CORROSION. REPAIRED LT AFT OVERWING ESCAPE HATCH CUTOUT BY FABRICATING AND INSTALLING A DOUBLER IAW SRM 53-30-3. (K)

RYN2008F00022

BOEING

 

 

NOSE COWL

DENTED

10/1/2008

727232

 

 

 

NR 3 NACELLE

NR 3 ENGINE NOSE COWL HAS DENT AT 5 OCLOCK POSITION, LEADING EDGE. REMOVED DENTED AREA AND ACCOMPLISHED NOSE COWL LEADING EDGE LIP SKIN REPAIR IAW SRM 54-30-1, 54-30-3, AND 51-30-2, 51-20-00, 51-31-00. (K)

RYN2008F00023

BOEING

 

 

STRUCTURE

CORRODED

10/1/2008

727232

 

 

 

HORIZONTAL STAB

RT HORIZONTAL STABILIZER TRAILING EDGE UPPER CHORD HAS CORROSION AT STABILIZER STA 189.68. REPLACED UPPER CHORD AT RT HORIZONTAL STABILIZER TRAILING EDGE IAW SRM 51-10-1 AND 51-30-3. (K)

PCSA2008093001

BOEING

 

 

ACTUATOR

LEAKING

9/30/2008

727233

 

 

269002911

NR 7 LE SLAT

LOST A HYDR SYS AFTER FLAP RETRACTION DEPARTING. ON APPROACH TO POS NR 7 L/E SLAT FAILED TO EXTEND. LANDING GEARS WERE EXTENDED MANUALLY, THE AC LANDED SAFELY AND WAS TOWED FROM THE RUNWAY. MAINT DISCOVERED THE NR 7 L/E ACTUATOR BODY HAD FAILED CAUSING A LOSS OF A SYS HYDR FLUID, A SYS FAILURE AND CONSEQUENT LOSS OF NOSE WHEEL STEERING. (K)

DHL2008F00032

BOEING

 

 

UNKNOWN

UNKNOWN

9/11/2008

727247

 

 

 

OVERSPEED WARN

DURING TAKEOFF ROLL OVERSPEED WARNING SOUND AT 70 KTS . DEFERRED IAW MEL 34-4-3 PULLED IAW CREW REQUEST. AIRCRAFT WAS GROUNDED. (K)

C8G2008F00011

BOEING

 

 

CONNECTOR

LOOSE

7/8/2008

7272A1

 

 

 

CSD

AFTER TAKEOFF DURING CLIMB OUT THE NR 1 GENERATOR EXPERIENCED A SPEED FAULT WITH THE NR 3 GENERATOR PREVIOUSLY DEFERRED. THE ACFT RETURNED TO DEPARTURE WHERE IT LANDED WITHOUT INCIDENT. POST FLIGHT INSPECTION WAS PERFORMED. NR NR 1 CSD A SPEED SWITCH CONNECTOR WAS RESEAT, RECRACKED GENERATOR CONTROL PANEL AND RESEAT CURRENT BREAKER. OPERATED ENGINE AND PERFORMED OPS CHECKS, CHECKED GOOD. O OTHER DEFECTS WERE NOTED AND THE AIRCRAFT WAS RETURNED TO SERVICE. (K)

 

 

DHL2008F00033

BOEING

 

 

FIRE LOOP

MALFUNCTIONED

9/18/2004

7272B7

 

 

 

MLG WW

IN CRUISE FLIGHT, HAD 3 INSTANCES OF MOMENTARY FIRE WARNING BELL WITH A FLICKER OF WHEEL WELL FIRE WARNING LIGHT. PERFORMED CONTINUITY TEST OF ENGINE AND WHEEL WELL FIRE LOOPS, TEST OK. INSPECTED WHEEL WELL WIRING AND FIRELOOPS, NO DEFECTS FOUND. COULD NOT DUPLICATE PROBLEM. REPLACED FIRE AND OVERHEAT ASSY UNIT AS PRECAUTIONARY IAW B727 MM 26-12-0, OPS CHECK OK. ACFT WAS GROUNDED. (K)

RYN2008F00016

BOEING

 

 

A/C PACK

MALFUNCTIONED

10/1/2008

737*

 

 

 

RIGHT

RT PACK TRIPPED. DEFERRED RT PACK. (K)

ASM2008F00004

BOEING

 

 

ACCESS PANEL

LEAKING

9/9/2008

737*

 

 

112N61012

RT FUEL TANK

DURING WALK AROUND CAPTAIN FOUND A FUEL LEAK UNDER THE RIGHT WING AND ENGINE FUEL DRAIN. MAINT CONFIRMED THE FUEL LEAK THEN REMOVED AND REPLACED MAIN TANK RIGHT WING ACCESS PANEL SEAL. 112N51012, DOOR ASSY ON RIGHT SIDE AND TESTED IAW MM 28-11-11M ALL CORRECT. (K)

SRO2008F00000

BOEING

 

 

SLIDE

INOPERATIVE

9/26/2008

737205

 

 

D31355440

R2 DOOR

DURING MINI EVACUATION DEMONSTRATION TRAINING SLIDE DEPLOYED BUT DID NOT INFLATE. WAITING ON TEAR DOWN REPORT FOR FINAL DISPOSITION.

KNN2008F00000

BOEING

 

 

BOLT

WORN

8/22/2008

737232

 

 

 

TRIM TAB HINGE

IN FLIGHT AGGRESSIVE VIBRATION FELT AT VARIOUS AIRSPEEDS 190 KTS-290 KTS, ALTITUDE STARTING AT 10,300 FT NOT RELENTING UNTIL WELL BELOW 190 KTS. (K)

KNN2008F00003

BOEING

 

 

STRINGER CLIP

DAMAGED

9/18/2004

737291

 

 

 

FUSELAGE

WHILE COMPLYING WITH AD 93-08-04 AND SB 737-53-1268. DURING THE CURRENT C-CHECK. WE FOUND STRINGER CLIP THAT FAILED NDT INSPECTION. THE STRINGER CLIP WAS REPLACED IAW SB-737-53-1268. ALL SUPPLEMENTAL INSPECTIONS WERE ALSO COMPLIED WITH IAW THE SB. (K)

KNN2008F00002

BOEING

 

 

BULKHEAD

CRACKED

9/9/2008

737291

 

 

 

BS 178

WHILE COMPLYING WITH AD 2000-05-29 PARA (A) DURING THE CURRENT C-CHECK, WE FOUND MULTIPLE CRACKS ON THE FWD PRESSURE BULKHEAD AT STA 178. DAMAGE WAS CUTOUT AND REPAIRED IAW SRM 53-10-10 FIG 1. (K)

KNN2008F00001

BOEING

 

 

SKIN

DENTED

9/9/2008

737291

 

 

 

BS 986-1016

DURING CURRENT C-CHECK, FOUND MULTIPLE DENTS ON FUSELAGE SKIN BETWEEN STA 986.5 TO 1016 FROM STR 14L TO 15. CUTOUT DAMAGE AND INSTALLED A REPAIR IAW MFG MESSAGE 1-915180265-1 AND ACO-085342 WITH AN 8100-9. (K)

SPA2008F00002

BOEING

PWA

 

BATTERY PACK

INOPERATIVE

9/17/2008

7372Y5

JT8D15

 

110049

EMERGENCY LIGHT

LOWER EMERGENCY EXIT LIGHT AT R1 AND L1 DOOR POSITIONS WILL NOT ILLUMINATE. REPLACED EMERGENCY LIGHT BATTERY PACK IAW MANUAL 33-21-27. FUNCTIONAL CHECK SATISFACTORY. (K)

SPA2008F00001

BOEING

PWA

 

BATTERY PACK

INOPERATIVE

9/17/2008

7372Y5

JT8D15

 

20131A

EMERGENCY LIGHTS

LOWER EMERGENCY LIGHTS AT DOORS L2 AND R2 WILL NOT ILLUMINATE. REPLACED EMERGENCY LIGHT BATTERY PACK IAW MM 33-21-27. FUNCTIONAL CHECK SATISFACTORY. (K)

SPA2008F00003

BOEING

PWA

 

POWER SUPPLY

FAILED

9/17/2008

7372Y5

JT8D15

 

110049

EMERGENCY LIGHT

LOWER EMERGENCY EXIT LIGHTS AT DOORS L2 AND R2 WILL NOT ILLUMINATE. REPLACED POWER SUPPLY IAW MM 33-21-27. FUNCTIONAL CHECK SATISFACTORY. (K)

SPA2008F00000

BOEING

PWA

 

BATTERY PACK

FAILED

9/1/2008

7372Y5

JT8D15

 

900835

EMERGENCY LIGHT

MID CABIN CEILING EMERGENCY EXIT LIGHTS WILL NOT ILLUMINATE. REPLACED BATTERY PACK AND POWER SUPPLY IAW MM 33-51-81. FUNCTIONAL CHECK SATISFACTORY. (K)

USAA920081674

BOEING

 

 

PIN

CORRODED

9/12/2008

7373B7

 

 

654611325

RT MLG TRUNNION

RT MLG TRUNNION PIN THREADS AND NUT BADLY CORRODED. REPLACED RT MLG TRUNNION PIN IAW MM 32-11-11. (K)

USAA920081659

BOEING

 

 

FRAME

CRACKED

9/4/2008

7373B7

 

 

65C22908

ZONE 100

FRAME CRACKED AT BS 500B BETWEEN S20R AND S21R. REPAIRED FRAME AT BS 500B BETWEEN S20R AND S21R IAW EA NR 100623. (K)

USAA9200816AA

BOEING

 

 

STIFFENER

CRACKED

8/25/2008

7373G7

 

 

654580731

ZONE 200

ANGLE STIFFENER CRACKED AT BS 289, S12R, WL 241 ABOVE WEB ATR1 DOOR CUTOUT. REPLACED ANGLE STIFFENER AT BS 289, S12R, WL 241 ABOVE WEB AT R1 DOOR CUTOUT IAW EA 130111. (K)

 

USAA920081676

BOEING

 

 

CHANNEL

CORRODED

8/21/2008

7373G7

 

 

BAC1509100146

ZONE 100

CORROSION ON CHANNEL BETWEEN BS 727B AND BS 747, LBL 3. REPAIRED CHANNEL BETWEEN BS 727B AND BS 747, LBL 3 IAW SRM 53-00-53. (K)

USAA920081675

BOEING

 

 

FLASHLIGHT

INOPERATIVE

9/9/2008

7373G7

 

 

P2070003001

ZONE 200

FORWARD FLIGHT ATTENDANT FLASH LIGHT IN-OP. REPLACED FORWARD FLIGHT ATTENDANT FLASH LIGHT. (K)

USAA920081665

BOEING

 

 

STRINGER CLIP

CRACKED

9/7/2008

7373G7

 

 

693535214

BS 380 S9R

STRINGER CLIP CRACKED AT BS 380, 9R. REPAIRED STRINGER CLIP AT BS 380, 9R IAW SRM 51-40-01-0G. (K)

USA2008F00030

BOEING

 

 

CHARGER

INOPERATIVE

9/13/2008

7373G7

 

 

20121

EMERGENCY LIGHT

MAINT REPORTED THE EXTERIOR EMERGENCY ESCAPE SLIDE LIGHT, AFT OF R2 DOOR, FAILS TO ILLUMINATE. MAINT INSTALLED A NEW CHARGER ASSY INCLUDING BATTERY PACK (M1137). OPS CHECK GOOD. (K)

USAA920081677

BOEING

 

 

FLOORBEAM

CORRODED

8/22/2008

7373G7

 

 

6546811

ZONE 100

CORROSION ON FLOORBEAM BETWEEN BS 986.5 TO 1006, RBL 15. REPAIRED FLOORBEAM IAW SRM 53-00-51. (K)

USA2008F00033

BOEING

 

 

MEGAPHONE

INOPERATIVE

9/10/2008

7373G7

 

 

MV10

AFT CABIN

MAINT REPORTED THE AFT CABIN MEGAPHONE INOPERATIVE. MAINT REMOVED AND REPLACED THE AFT CABIN MEGAPHONE. OPS CHECK GOOD. (K)

USAA920081673

BOEING

 

 

WEB

CRACKED

8/22/2008

7373G7

 

 

6545409306

BS 665.75

PRESSURE WEB CRACKED AT BS 665.75 WL 200, LBL 32. REPAIRED PRESSURE WEB AT BS 665.75, WL 200. (K)

USAA920081672

BOEING

 

 

STIFFENER

CRACKED

8/25/2008

7373G7

 

 

654580730

BS 289 S11R

ANGLE STIFFENER CRACKED AT BS 289, S11R, WL253 BELOW R1 DOOR CUT OUT. REPLACED ANGLE STIFFENER AT BS 289, S11R, WL253 BELOW R1 DOOR CUTOUT IAW EA 13011. (K)

USA2008F00031

BOEING

 

 

WIRE

BROKEN

9/15/2008

7373G7

 

 

 

EMERGENCY LIGHTS

MAINT REPORTED THE EMERGENCY ESCAPE PATH LIGHT ON SEAT ROW 22, LT SIDE, INOPERATIVE. MAINT TROUBLESHOT AND FOUND A BROKEN WIRE. OPERATIONAL CHECK GOOD. (K)

USAA920081670

BOEING

 

 

STIFFENER

CRACKED

8/25/2008

7373G7

 

 

654580724

BS 289 S13R

ATTACH ANGLE CRACKED ABOVE WEB AT R-1 DOOR CUTOUT AT BS 289, S13R, WL 235. REPLACED ATTACH ANGLE ABOVE WEB AT R-1 DOOR CUTOUT AT BS 289, S13R, WL 235 IAW EA NR 130111. (K)

USAA920081680

BOEING

 

 

FRAME

CRACKED

8/21/2008

7373G7

 

 

6546555

ZONE 100

EXFOLIATION CORROSION ON FRAME AT BS 867, BL 0. REPAIRED FRAME AT BS 867, BL 0 IAW SRM 53-00-07-2R.

USA2008F00032

BOEING

 

 

WIRE

BROKEN

9/15/2008

7374B7

 

 

 

EMERGENCY LIGHTS

MAINT REPORTED THE SEAT MOUNTED EMERGENCY LIGHTS FROM SEAT ROWS 20 TO 25 INOPERATIVE. MAINTENANCE FOUND A BROKEN WIRE. SPLICED WIRES TOGETHER. OPERATIONAL CHECK GOOD. (K)

USAA920081681

BOEING

 

 

SKIN

CRACKED

9/14/2008

7374B7

 

 

 

ZONE 300

LT HORIZONTAL LOWER SKIN CRACKED ALONG AFT SPAR CAP. ACCOMPLISHED TEMPORARY REPAIR IAW REPAIR NR 55-10-08. REPAIRED LT HORIZONTAL LOWER SKIN CRACKED ALONG AFT SPAR CAP 55 INCHES FROM THE ROOT AREA IAW B737 SRM 55-10-07.

USAA920081660

BOEING

 

 

FRAME

CRACKED

9/10/2008

7374B7

 

 

6546529

ZONE 200

FRAME CRACKED AT SUPPORT BRACKET BS440 BETWEEN S8R AND S9R. REPAIRED FRAME AT SUPPORT BRACKET BS 440 BETWEEN S8R AND S9R IAW REPAIR NR 53-10-20E. (K)

USAA920081661

BOEING

 

 

FRAME

CRACKED

9/8/2008

7374B7

 

 

 

BS 616 S17L

FUSELAGE FRAME CRACKED ON INNER CHORD STRAP AT LOWER END BS 616, S17L. REPAIRED FUSELAGE FRAME ON INNER CHORD STRAP AT LOWER END BS616, S17L IAW AMM 2015-05 AND REPAIR 53-62-01. (K)

 

USA2008F00029

BOEING

 

 

WIRE

BROKEN

9/13/2008

7374B7

 

 

 

EMERGENCY LIGHT

MAINTENANCE REPORTED THE EMERGENCY ESCAPE PATH LIGHTING FROM SEAT ROWS 19 TO 25, LT SIDE, INOPERATIVE. MAINT REPAIRED WIRING AT SEAT ROW 25 IAW STANDARD PRACTICES. EMERGENCY LIGHTING OPERATIONALLY CHECKS SATISFACTORY. (K)

USAA920081668

BOEING

 

 

FRAME

CRACKED

9/10/2008

7374B7

 

 

BOEING

BS 601 S17R

FUSELAGE FRAME CRACKED ON INNER CHORD AT BS601, S17R. REPAIRED FUSELAGE FRAME INNER CHORD AT BS 601, S17R IAW TYPICAL REPAIR 53-62-01. (K)

USAA920081678

BOEING

 

 

FRAME

CRACKED

9/13/2008

7374B7

 

 

6546525

ZONE 100

CRACKS EMANATING FROM FASTENERS AT FRAME 380 BETWEEN S20L AND S21L. REPAIRED FRAME 380 BETWEEN S20L AND S21L IAW TYPICAL REPAIR NR 53-60-07. (K)

USAA920081656

BOEING

 

 

SKIN

CRACKED

9/10/2008

7374B7

 

 

6545774

ZONE 100

FUSELAGE SKIN CRACKED AT BS 727E+4, S22L AND BS 727E+16, S23L. REPAIRED FUSELAGE SKIN AT BS 727E+4, S22L AND BS 727E+16, S23L IAW SRM 53-00-01, REPAIR 31, TEMPORARY REVISION 53-27. (K)

USAA920081666

BOEING

 

 

SKIN

DELAMINATED

9/3/2008

7374B7

 

 

 

SPOILER

LT WING NR 0 SPOILER DELAMINATED ON UPPER SURFACE. REPLACED LT WING NR 0 SPOILER IAW AMM27-62-91. (K)

SCN2008F00000

BOEING

 

 

FUSIBLE PLUG

BLOWN

8/2/2008

7378BK

 

 

 

WHEEL

DURING TAXI-IN, CREW REPORTED LT OB MAIN WHEEL ASSY/ BRACE DRAGGING. MAINT DISCOVERED NR 1 WHEEL ASSY FUSE PLUG BLOWN. REMOVED AND REPLACED NR 1 WHEEL/TIRE ASSY AND NR 1 BRAKE ASSY. (K)

KCS2008F00009

BOEING

 

 

SKIN

CRACKED

9/14/2008

747122

 

 

 

BS 2678

FASTENER HEAD MISSING AND SKIN CRACKED UPPER AFT CORNER OF APU INLET OPENING. (K)

KCS2008F00012

BOEING

 

 

FLOORBEAM

DAMAGED

9/13/2008

747122

 

 

 

BS 600

FORWARD BILGE FLOORBEAM UPPER CHORD IS DAMAGED AT STA 600, RBL 21. (K)

KCSA081488

BOEING

 

 

FLOORBEAM

CRACKED

9/22/2008

747122

 

 

 

BS 1740

AFT PIT FLOORBEAM UPPER T-CHORD CRACKED AT BS 1740, RBL 27. (K)

KCSA081486

BOEING

 

 

FRAME

DENTED

9/22/2008

747122

 

 

 

BS 1780 S10R

FUSELAGE FRAME DENTED AT BS 1780, STR10R. (K)

KCS2008F00013

BOEING

 

 

FRAME

CRACKED

9/13/2008

747122

 

 

 

BS 1820, RBL 11

AFT BILGE FRAME WEB IS CRACKED AT STA 1820, RBL 11. (K)

KCSA081497

BOEING

 

 

SKIN PANEL

BULGED

9/27/2008

747122

 

 

 

RT WING

RT WING UPPER T/E PANEL HAS BULGE ABOVE REAR SPAR AT WBL 241. (K)

KCSA081487

BOEING

 

 

SUPPORT ANGLE

DAMAGED

9/22/2008

747122

 

 

 

BS 1640 S23R

FUSELAGE FRAME SUPPORT T-DAMAGED AT BS 1640, STR 23R. (K)

KCS2008F00010

BOEING

 

 

LIGHT

INOPERATIVE

9/13/2008

747123

 

 

 

CABIN

L-5 DOOR SILL EMERGENCY EXIT LIGHTS INOPERATIVE. (K)

KCS2008F00011

BOEING

 

 

LIGHT

INOPERATIVE

9/13/2008

747123

 

 

 

CABIN

MAIN DECK STA 2290 OVERHEAD EMERGENCY EXIT LIGHTS INOPERATIVE. (K)

 

EIA2008052

BOEING

 

 

SKIN

CRACKED

9/5/2008

747132

 

 

 

R3 DOOR

R3 DOOR LOWER FWD CORNER BS 1275 CRACKS IN SKIN FASTENER HOLES. REMOVED DAMAGE, NOT AREA, FABBED AND INSTALLED REPAIR IAW ECRA 479-53-225-2.

EIA2008053

BOEING

 

 

SKIN

CRACKED

9/5/2008

747132

 

 

 

L3 DOOR

L3 DOOR LOWER FWD. CORNER BS 1275 CRACKS IN SKIN FASTENER HOLES. REMOVED DAMAGE, NDT AREA, FABBED AND INSTALLED REPAIR IAW ECRA 479-53-225-2. (K)

KCSA081446

BOEING

 

 

LIGHT

INOPERATIVE

9/5/2008

747146

 

 

 

CABIN

RT EMERGENCY EXIT LIGHT INOPERATIVE ON THE UPPER DECK STA 590. (K)

EIA2008050

BOEING

 

 

WIRE

DAMAGED

9/17/2008

747212B

 

 

 

EMERGENCY LIGHTS

(2) EACH EMERGENCY LIGHT ON UPPER DECK CEILING ARE OUT. EMERGENCY LIGHT ASSY U/D AFT REPLACED IAW MM 33-51-00. OPS CHECKED NORMAL. REPAIRED WIRE AT PIN NR 3 BROKEN AT KITE ASSY IAW STANDARD PRACTICES ALSO REPAIRED PIN IAW MANUAL OPS CHECKED NORMAL. (K)

KCSA081485

BOEING

 

 

SEAT TRACK

CRACKED

9/22/2008

747221F

 

 

 

BS 1910

AFT PIT SEAT TRACK CRACKED AT BS 1910, RBL 46. (K)

KCS2008F00014

BOEING

 

 

FRAME

CRACKED

9/13/2008

747221F

 

 

 

BS 2231 S21-22L

MAIN DECK L5 DOOR REVEAL IS CRACKED (2") AT STA 2231 BETWEEN STR 21L AND 22L. (K)

UIEA200800308

BOEING

 

 

SKIN

CRACKED

9/16/2008

747230B

 

 

65B393001

KRUEGER FLAP

LT WING LEADING EDGE KRUEGER FLAP LOWER IB SIDE PANEL AT WING STA 323.00 TO 330.00 HAS A 7.0 INCH COMPOSITE CRACK. PERMANENT REPAIR ACCOMPLISHED IAW SRM 51-40-09, FIG 3, SHEETS 1, 4 AND 8, PREPEG 250 DEGREES F CURE IAW SRM 51-40-12. ALSO, REFERENCE EO NR 4757A464.

UIEA200800309

BOEING

 

 

FRAME

CRACKED

9/16/2008

747230B

 

 

146U7756U2

BS 1780

MAIN DECK CARGO COMPARTMENT SIDEWALL FRAME AT BS 1780 AT S12R HAS A 6.0 INCH CRACK, TOTAL WIDTH OF FRAME. INTERIM REPAIR ACCOMPLISHED IAW SRM 51-30-02 EO NR 4753B208 AND FORM 8110-3. REQUIRES INITIAL AND REPEAT INSPECTIONS AT EVERY C-CHECK INTERVALS. (K)

UIE2008F00044

BOEING

 

 

ISOLATION VALVE

FAILED

9/8/2008

747230B

 

 

73836222

ENGINE

AIR TURN BACK. DURING CLIMB BOTH LT AND RT MANIFOLD PRESSURE WAS FLUCTUATING. DURING TROUBLESHOOTING AFTER CRUISE POWER SET 103.4, THE NR 1,3, AND 4 PYLONS VALVES WOULD NOT CLOSE. WITH LT AND RT ISOLATION VALVES CLOSED, IT WAS DETERMINED THAT THE NR 1 PYLON VALVE WAS PARTIALLY OPEN WITH 8 PSI. THE NR 3 AND NR 4 INDICATED STUCK FULL OPEN WITH 38 PSI. APPROX 76.0 KG OF FUEL JETTISONED. NR 1,NR 3 AND NR 4 PYLON VALVES REPLACED AND ALL OPERATIONS NORMAL. ALSO NR 3 PRESSURE REGULATING VALVE REPLACED AND OPS CHECKED OK. WIRING CHECKS ALSO ACCOMPLISHED AND CHECKED OK. (K)

EIA2008F00003

BOEING

GE

 

ENGINE

STALLED

9/4/2008

747230B

CF650E2

 

CF650E2

NR 3

DURING TAKEOFF EGT`S WERE PEAK 934,908,908,913 ON ENG`S ONE THRU FOUR. AUTO THROTTLES WERE ON. AFTER REDUCTION TO CLIMB POWER, PASSING THRU 1800`, IN LEFT TURN WE HEARD A LOUD BANG ACCOMPANIED WITH AN AIRCRAFT SHUDDER. NOTICED NR 3 N1 ROLLING BACK WITH N2 ROLLING BACK. NOTICED EGT DECREASING THRU 930 C. EGT GAGE OVERTEMP NEEDLE STOPPED AT 955 C. SHUTDOWN NR 3 ENGINE. DECLARED AN EMERGENCY, DUMPED FUEL TO GW OF 630,000. RETURNED TO DEPARTURE FOR UNEVENTFUL LANDING ON RWY 36. FUEL DUMPED. REMOVED AND REPLACED ENGINE IAW WITH EIA WORK CARD F7201-CF6. (K)

KCSA081500

BOEING

 

 

SKIN

DAMAGED

9/30/2008

747236B

 

 

 

NR 2 PYLON

NR 2 PYLON INBD LOWER SKIN DAMAGED AT NAC STA 194. (K)

UIEA200800299

BOEING

 

 

INU

FAILED

9/6/2008

747243B

 

 

46300161300413

NR 1

AIR TURN BACK, DURING CLIMBOUT BOTH INST WARNING LIGHTS WITH ATT LIGHT ILLUMINATED. CAPT`S ADI ATT AND COMPAS FLAG IN VIEW. CAPTS HSI HDG, FLAG IN VIEW. REMOVED AND REPLACED NR 1 INU IAW 34-41-03. COOLING SYSTEM TESTED OK AND INS NAV TEST OK. (K)

UIEA200800310

BOEING

 

 

SKIN

PUNCTURED

9/18/2008

747243B

 

 

 

BS 430 S37R

DURING GROUND OPERATION IN FUSELAGE SKIN, STA 430, STRINGER 37R NEAR THE GROUND POWER RECEPTACLE WAS STRUCK CAUSING DAMAGE CONSISTING OF A PUNCTURE MEASURING 3X6 INCHES. INTERIM REPAIR ACCOMPLISHED IAW EO 4753B209. (K)

KCSA081504

BOEING

 

 

FRAME

CORRODED

9/30/2008

747249F

 

 

 

PYLON

NR PYLON NAC STA 221.9 BULKHEAD RT FWD FRAME WEB CORRODED. (K)

KCSA081498

BOEING

 

 

FRAME

CORRODED

9/27/2008

747249F

 

 

 

FUSELAGE

AFT BILGE FUSELAGE FRAME UPPER CHORD IS CORRODED AT STA 1880, RBL 18. (K)

 

KCSA081501

BOEING

 

 

FRAME

CRACKED

9/30/2008

747249F

 

 

 

NR 3 PYLON

NR 3 PYLON NAC STA 221.9, BULKHEAD RT AFT FRAME WEB CRACKED AT (2) SPOTS. 750 AND .250. (K)

KCSA081502

BOEING

 

 

FRAME

CRACKED

9/30/2008

747249F

 

 

 

NR 3 PYLON

NR 3 PYLON NAC STA 221.9 BULKHEAD LT AFT FRAME WEB CRACKED. (K)

KCSA081503

BOEING

 

 

DOUBLER

CORRODED

9/30/2008

747249F

 

 

 

NR 3 PYLON

NR 3 PYLON NAC STA 221.9 BULKHEAD FWD FRAME WEB DOUBLERS CORRODED. (K)

KCS2008F00015

BOEING

 

 

SKIN

CORRODED

9/13/2008

747249F

 

 

 

BS 1960-2180

FUSELAGE SKIN HAS CORROSION AROUND FASTENER HEADS AT STA 1960 TO 2180, STR 46R. (K)

KCS2008F00016

BOEING

 

 

DOOR FRAME

CRACKED

9/4/2008

747249F

 

 

 

BS 281

STA 281, RBL-50, W/L-312 CARGO DOOR FRAME CRACKED. (K)

KCS2008F00017

BOEING

 

 

SEAT TRACK

CORRODED

9/12/2008

747249F

 

 

 

BS 620

SEAT TRACK AT STA-620 AT LBL-70 CORRODED. (K)

KCS2008F00018

BOEING

 

 

STRINGER

CORRODED

9/12/2008

747249F

 

 

 

BS 990 S46L

STRINGER 46-L CORRODED AT STA-990. (K)

KCSA081505

BOEING

 

 

FRAME

CORRODED

9/30/2008

747249F

 

 

 

NR 3 PYLON

NR 3 PYLON NAC STA 221.9 BULKHEAD LT FWD FRAME WEB CORRODED. (K)

KCSA081496

BOEING

 

 

SKIN

CORRODED

9/27/2008

747249F

 

 

 

FUSELAGE

FUSELAGE SKIN IS CORRODED AT STA 2362, BETWEEN STR 40L AND 46L. (K)

KCSA081499

BOEING

 

 

SKIN

DAMAGED

9/30/2008

747259B

 

 

 

PYLON

NR PYLON OTBD SKIN LOWER FASTERNER HOLES DAMAGED AT NAC 221.9. (K)

UIE2008F00042

BOEING

 

 

SKIN

CORRODED

9/14/2008

7472D7B

 

 

 

FUSELAGE

CENTER SECTION UPPER SKIN PANEL AT REAR SPAR LBL 100.0, LBL 108.65 CORROSION. REPAIRED IAW MFG SERVICE REQUEST 1-957658161 APPROVED BY FORM 8100-9 DATED 9 SEPT 2008, DETAILS OF WORK KEPT AT EO-4752A462. (K)

UIE2008F00038

BOEING

 

 

DOOR FRAME

CRACKED

9/14/2008

7472D7B

 

 

 

FUSELAGE

LT NR 1 MAIN ENTRY DOOR FWD FRAME UPPER HINGE CUTOUT AREA CRACKED. REPAIRED IAW MFG SERVICE REQUEST 1-948230971 APPROVED BY FORM 8100-9 DATED 4 SEP, 2008, DETAILS OF WORK KEPT AT EO-4752A153. (K)

UIE2008F00039

BOEING

 

 

BEAM

CORRODED

9/14/2008

7472D7B

 

 

 

FUSELAGE

RT NR 5 MAIN ENTRY DOOR FWD EDGE BEAM AND LOWER HINGE CUTOUT AREA CORROSION. REPAIRED IAW SERVICE REQUEST 1-954744333 APPROVED BY FORM 8100-9 DATED 5 SEPT, 2008, DETAILS OF WORK KEPT AT EO-4752A154. (K)

UIE2008F00041

BOEING

 

 

FRAME

DENTED

9/14/2008

7472D7B

 

 

 

BS 1740 S12-13R

BS 1740 FRAME BETWEEN S-12R AND S-13R DENT. REPAIRED IAW MFG SERVICE REQUEST 1-954640770 APPROVED BY FORM 8100-9 DATED 12 SEP 2008, DETAILS OF WORK KEPT AT EO -4753B201. (K)

UIE2008F00040

BOEING

 

 

FRAME

DENTED

9/14/2008

7472D7B

 

 

 

BS 1780 S12-13R

BS 1780 FRAME BETWEEN S-12R AND S-13R DENT. REPAIRED IAW MFG SERVICE REQUEST 1-954640956 APPROVED BY FORM 8100-9 DATED 12 SEPT 2008, DETAILS OF WORK KEPT AT EO 4753B201. (K)

 

UIE2008F00037

BOEING

 

 

RELIEF VALVE

FAILED

 

9/12/2008

747341

 

 

227565M2

NR 3 ENGINE

 

AIR TURN BACK. DURING CLIMB AT APPROX FL 230, NR 3 ENGINE FIRE HANDLE ILLUMINATED. ACCOMPLISHED FHB ENGINE FIRE PROCEDURES. LIGHT EXTINGUISHED AFTER THRUST LEVER SET TO IDLE. INCREASE IN NACELLE TEMP INSPECTION CARRIED OUT IAW AMM. FOUND PRESSURE RELIEF AT FAULT. REMOVED AND REPLACED VALVE OPS CHECKED AND LEAK CHECKED OK. (K)

EIA2008F00004

BOEING

 

 

STRINGER

CRACKED

 

8/22/2008

747409

 

 

 

BS 480-499 S10L

 

BS 480-499 STRINGER 10 LT STRINGER IS CRACKED. REPAIRED CRACKED STRINGER AT BS 480 & 500 IAW SB747-53A2484, FIG 18 AND 20. (K)

NWAA084196309

BOEING

 

 

WIRE

LOOSE

 

9/8/2008

747451

 

 

 

EMERGENCY LIGHT

 

DURING OVER NIGHT CHECK, FOUND EMERGENCY FLOOR LIGHTS FROM ROW 51 TO 65 ABC INOPERATIVE. MAINTENANCE REPAIRED LOOSE WIRE AT PIN CONNECTION. OPS CHECKED GOOD, AND AIRCRAFT WAS RETURNED TO SERVICE. (K)

P5CA0801575

BOEING

GE

 

SHUTOFF VALVE

DEFECTIVE

 

8/31/2008

74746NF

CF680

 

 

NR 1 ENGINE

 

NR 1 ENGINE AUTO START FAILED. TROUBLESHOT AND FOUND NR 1 PRSOV DEFECTIVE AMM36-11-04. (K)

UIE2008F00035

BOEING

 

 

SHIM

MIGRATED

 

9/18/2008

74747UF

 

 

 

RT MLG WW

 

SHIM MIGRATION AT RT BODY GEAR W/W FUSELAGE LONGERON STRUCTURE STATION 1468-1480. SHIM REPLACED IAW SRM 51-20-08, REV 48, SR ID NR 1-937881538 AND EO NR 4453A203. (K)

UIE2008F00034

BOEING

GE

 

SKIN

DAMAGED

 

9/18/2008

74747UF

CF680C2B6

 

86B07662162

BS 380-440

 

DURING PFM J/C: MCIA016, REPLACE 6 BLIND FASTENER FOUND DEVIATION FOR STA 380, 440, S-1R MISS DRILLING HOLE. ACCOMPLISHED THE SEA DOUBLER HOLES ON SKIN COMMON TO THE STRAP AT BS 380, 440, AND 480 BETWEEN S1R AND A2R. (K)

UIE2008F00031

BOEING

GE

 

SKIN

DENTED

 

9/18/2008

74747UF

CF680C2B6

 

146U70053

FUSELAGE

 

DENT WAS FOUND AT THE AFTER LOWER CORNER OF BULK CARGO DOOR. INSPECTED IAW SRM 51-10-00 AND SR ID NR 1949639862. (K)

UIE2008F00033

BOEING

GE

 

FAIRING

DAMAGED

 

9/18/2008

74747UF

CF680C2B6

 

3234538733

NR 4 NACELLE

 

FOUND NR 4 ENGINE SKIRT FAIRING SUPPORT BRACKET ATTACHED BOLT IB SIDE HOLE ENLARGED NEAR FAIRING DOOR NR 4 HINGE. REPAIR ACCOMPLISHED IAW SR ID NR 1945402461 AND EO NR 4464A066. (K)

UIE2008F00032

BOEING

GE

 

SKIN

CRACKED

 

9/18/2008

74747UF

CF680C2B6

 

2242302545

NR 3 NACELLE

 

FOUND NR 3 ENGINE RT CORE COWL LOWER FACE CRACKED. 0.3 INCH AT NAC STA 288. REPAIRED IAW FORM NR E8207.4. (K)

UIE2008F00029

BOEING

GE

 

STRINGER

CORRODED

 

9/18/2008

74747UF

CF680C2B6F

 

BAC1498143

BS 2588 S46R

 

FOUND RT FUSELAGE INNER STRINGER CORROSION AT STA 2580, S46R. REPAIRED RT FUSELAGE INNER STRINGER AT STA 2588, S-46R, IAW 747-400F SRM 53-00-03, FIG 201 REV 48 AND EO NR 4463A209. (K)

UIE2008F00030

BOEING

GE

 

WEB

CANNING

 

9/18/2008

74747UF

CF680C2B6F

 

7075T6020

BS 1800

 

AFT CARGO COMPARTMENT FOUND FRAME WEB ALL CAN AT STA 1800, LBL 17 INCHES, S:60L. REPAIRED FRAME WEB OIL CAN AREA AT AFT CARGO COMPARTMENT STA 1800, LBL 16 TO LBL 20S:50L, FABRICATED IAW SRM 63-00-07, REV 48 AND SRM 51-40-02 REV 48 AND EO NR 4453A207. (K)

RYN2008F00019

BOEING

 

 

LINE

BROKEN

 

9/11/2008

757200

 

 

 

P1 PROBE

 

LT ENGINE EPR INDICATION BLANKING OUT AND ENGINE HAS LOW POWER. REPLACED THE LT ENGINE P1 PROBE BROKEN SENSE LINE. COMPLIED WITH HIGH POWER ENGINE RUN, NO DEFECT NOTED. (K)

RYN2008F00018

BOEING

 

 

SLIDE

UNWANTED DEPLOY

 

9/11/2008

757236

 

 

 

 

 

F/O ACCIDENTALLY BLEW L1 DOOR SLIDE. C/A IN WORK. (K)

RYN2008F00021

BOEING

 

 

LINE

BROKEN

 

9/10/2008

757236

 

 

 

P1 PROBE

 

PILOT REPORT LT ENGINE NOT MAKING POWER AT FL 20000 WITH THE ENGINE POWER LEVER FULLY FWD AND N1 WAS ONLY 71 PERCENT. REPLACED THE LT ENGINE P1 PROBE BROKEN SENSE LINE. COMPLIED WITH HIGH POWER ENGINE RUN, NO DEFECT NOTED. (K)

NWAA084215517

BOEING

 

 

BATTERY PACK

INOPERATIVE

 

9/11/2008

757251

 

 

 

EMERGENCY LIGHT

 

DURING THE EMERGENCY LIGHT CHECK AS A PART OF AN OVERNIGHT LINE CHECK, THE ESCAPE SLIDE ILLUMINATION LIGHT AT DOOR 3L FAILED. MAINTENANCE REPLACED BATTERY PACK POWER SUPPLY M735, ALL OPERATIONS WERE NORMAL AFTER REPLACEMENT OF THE BATTERY PACK. (K)

 

NOC2008F00005

BOEING

 

 

BUSS

OVERHEATED

9/21/2008

75728A

 

 

 

 

ACFT DIVERTED TO STL, SMOKE IN COCKPIT EMERGENCY DECLARED CAPT REPORTS THE RT ACFT BUSS OVERHEATED ITEM REMAINS OPEN. (K)

NOC2008F00006

BOEING

 

 

UNKNOWN

SMOKE

9/17/2008

75728A

 

 

 

CABIN

AT FL90 WITH AUTOPILOT ENGAGED ACFT HAD AN OVERSPEED OF 10 KTS AT THE SAME TIME F/A CALLED SMOKE IN CABIN. HAD AN UNEVENTFUL LANDING, DECLARED AN EMERGENCY. INSPECTED ACFT EXTERIOR STRUCTURE, AFT FUSELAGE, BULKHEAD, STAB FITTINGS, JACKSCREW AREA NO DAMAGE FOUND NO BUCKLES OR CRACKS. EXAMINED ENGINE PANELS, DOORS AND LOWER SURFACES IAW MM 05-51-04-212-019 UNABLE TO DUPLICATE THE SMOKE IN CABIN. CHECKED BOTH PACK BAYS, ALL CARGO BAYS, LAVS, E/E COMPARTMENTS NO SIGNS OF HEAT. AIRCRAFT OK FOR SERVICE. (K)

USA2008F00025

BOEING

 

 

FLAP SYSTEM

MALFUNCTIONED

9/12/2008

7572B7

 

 

 

TE FLAPS

DURING CLIMBOUT, THE CREW RECEIVED AN ASYMMETRICAL TRAILING EDGE FLAP DISAGREE MESSAGE. THE CREW DECIDED TO RETURN TO FIELD. THE FLIGHT LANDED WITHOUT FURTHER INCIDENT. MAINTENANCE ACTION PENDING. (K)

RYN2008F00013

BOEING

 

 

ANTENNA

FAILED

9/1/2008

7572G5

 

 

 

WX RADAR SYS

AIR TURN BACK DUE TO WEATHER RADAR FAILED BEFORE ENTERING ETOPS AIRSPACE. REMOVED WATER FROM THE ANTENNA RESET THE SYSTEM OPS CHECKED NORMAL. (K)

RYN2008F00020

BOEING

 

 

SENSE LINE

BROKEN

9/10/2008

7572G5

 

 

 

LT ENGINE

PILOT REPORT LT ENGINE NOT MAKING POWER AT FL 20000 WITH THE ENGINE POWER LEVER FULLY FWD AND N1 WAS ONLY 71 PERCENT. REPLACED THE LT ENGINE P1 PROBE BROKEN SENSE LINE. COMPLIED WITH HIGH POWER ENGINE RUN, NO DEFECT NOTED. (K)

RYN2008F00014

BOEING

 

 

IDG

FAILED

10/1/2008

7572G5

 

 

 

 

IDG FAILED NO FREQUENCY OR VOLT. REPLACED IDG IAW AMM 24-11-1. CHECKED GOOD. (K)

RYN2008F00015

BOEING

 

 

ADI

FAILED

10/1/2008

7572G5

 

 

 

 

F/O ADI BANKING OUT INTERMITTENTLY. REPLACED F/O ADI. (K0

ABXA080232

BOEING

 

 

SEAT

DEFECTIVE

8/19/2008

767232

 

 

824250611

COCKPIT

CAPTAINS ELECTRICAL SEAT UNOP. FORE AND AFT, UP AND DOWN, SEAT LOCK RELEASED WHEN APPLYING BRAKES ALLOWING SEAT TO SLIDE AFT UNCONTROLLABLY. REPLACED CAPTAINS SEAT WITH SERVICEABLE UNIT. OPS CHECK OK. IAW B767 MM 25-11-02.

ABXA080236

BOEING

 

 

BATTERY

DISCHARGED

9/4/2008

767281

 

 

20131A

E&E BAY

EMERGENCY LIGHT INOPERATIVE. SWAPPED EMERGENCY BATTERY WITH SPARE BATTERY. IAW B767 AMM 33-51-00.

ABXA080241

BOEING

 

 

SKIN

BULGED

8/29/2008

767281

 

 

 

BS 1307 L25-26L

SKIN BULGING AROUND RIVETS AT STA 1307L, LONG 26-25L. REPAIRED SKIN IAW ABXAIR REA B653-57726 MR.

ABX2008F00003

BOEING

GE

 

SPINNER

LEAKING

9/3/2008

767281

CF680A

 

 

NR 1 ENGINE

EXHAUST FUMES IN COCKPIT DURING HIGH THRUST SETTINGS. GROUND RAN ENGINES AND FOUND LEFT ENGINE PRODUCING SMOKE EXHAUST FUMES FROM VENTS WITH LEFT BACK ON. FOUND OIL IN NR 1 ENGINE SPINNER. RESEALED NR 1 BEARING MANIFOLD AND FAN ROTOR SPINNER IAW AMM 72-31-00-2 AND 72-31-01-4. (K)

ANCF200800019

BOEING

 

 

APU

MALFUNCTIONED

8/18/2008

767283ER

 

 

 

 

AIR TURN BACK, EICAS MSG 02 "R GEN OFF" DISPLAYED, R GEN OFF LIGHT ILLUMINATED. GENERATOR SWITCH RESET DID NOT CORRECT CONDITION. APU WAS TRANSFERRED TO DMI N. 247 BY MAINT REPORT P4264038-X3. : "APU FAIL". PERFORMED BPCU BITE TEST IAW FIM PROCEDURE 24-20-00, PG 180K. ACCOMPLISHED BOTH ENGINES RUN UP, ALL ELECTRICAL PARAMETERS WERE NORMAL. RT ENGINE IDG IS CONSIDERED OPERATIVE. SERVICED APU OIL TANK AS REQUIRED IAW AMM 12-13-04 PAGE 301, ACCOMPLISHED ERASE BITE PROCEDURE IAW FIM 49-11-01, PAGE 401. CHECKED APU OPERATION. WORKING PROPERLY. (K)

USA2008F00026

BOEING

 

 

ACTUATOR

INOPERATIVE

9/11/2008

7672B7

 

 

863424

PAX DOOR

THE FWD R1 ENTRY DOOR BAR ASSY SPRING RETRACT ACTUATOR WAS FOUND INOPERATIVE DURING THE SLIDE DEPLOYMENT CHECK. MAINT REPLACED FWD R1 ENTRY DOOR BAR ASSY SPRING ACTUATOR. OK FOR SERVICE. (K)

ANCF200800022

BOEING

 

 

DRIVE ASSY

INTERMITTENT

8/30/2008

767383

 

 

20414440406

WX RADAR ANTENNA

AIR TURN BACK DUE REPORT: "WXR FAIL DISPLAYED ON HSI WITH 02=R SYSTEM SELECTED. WXR FAIL ANTENNA ON HSI. NOTE: PREVIOUSLY REPORTED ON FLIGHT 020 OF 8/30/2008. SWEEP (GHOST IMAGE WITH) ON HSI, WEATHER DISPLAY WITH 03=R BOTH SYSTEM SELECTED. NOTE: PREVIOUSLY REPORTED ON FLIGHT 020 OF 8/30/2008 AND FLIGHT 081 OF 8/29/2008. WXR FAIL DISPLAYED ON HSI WITH 05 BOTH SYSTEM SELECTED. WXR FAIL ANT ON HSI." PERFORMED FIM 34-43-00, FIG 103 CONFIRMED WXR ANTENNA FAULT. R/R WXR ANTENNA. IAW 34-43-05/401 TST OK ON BOTH SYSTEM. AC OK FOR SERVICE. (K)

AALA200802273

BOEING

 

 

CONNECTOR

LOOSE

9/5/2008

777223

 

 

 

CABIN

EMERGENCY LIGHTS AT SEAT ROWS 4A TO LAVATORY NR 2, INOPERATIVE. SECURED CONNECTOR FOR EMERGENCY LIGHTS AT SEAT ROWS 4A TO LAVATORY NR 2. SYSTEM GROUND CHECKED NORMAL OPERATION. (K)

 

AALA200802265

BOEING

 

 

LENS

MISSING

9/3/2008

777223

 

 

 

CABIN

EMERGENCY LIGHT AT SEAT 34C MISSING LENS. REPLACED LENS FOR EMERGENCY LIGHT AT SEAT 34C. SYSTEM GROUND CHECKED NORMAL OPERATION. (K)

AALA200802264

BOEING

 

 

LENS

MISSING

9/3/2008

777223

 

 

 

CABIN

EMERGENCY LIGHT AT SEAT 22C MISSING LENS. REPLACED LENS FOR EMERGENCY LIGHT AT SEAT 22C. SYSTEM GROUND CHECKED NORMAL OPERATION. (K)

AALA200802274

BOEING

 

 

CONNECTOR

LOOSE

9/5/2008

777223

 

 

 

CABIN

EMERGENCY LIGHTS AT SEAT ROWS 4J TO 8H INOPERATIVE. SECURED CONNECTOR FOR EMERGENCY LIGHTS AT SEAT ROWS 4J TO 8H. SYSTEM GROUND CHECKED NORMAL OPERATION. (K)

AALA200802275

BOEING

 

 

LENS

MISSING

9/5/2008

777223

 

 

0201804001

CABIN

EMERGENCY LIGHTS AT SEAT 20G MISSING LENS. REPLACED LENS FOR EMERGENCY LIGHTS AT SEAT 20G. SYSTEM GROUND CHECKED NORMAL OPERATION. (K)

ASM2008F00005

BOEING

GE

 

HOSE

DAMAGED

9/13/2008

7772Q8

GE9092B

 

AE70970110

HYD SYSTEM

DURING TRANSIT CHECK, MAINT DETECTED DAMAGE AND HYDRAULIC LEAK ON SUPPLY HOSE ASSEMBLY TO RT ENGINE EDP. THE HOSE ASSY, PN AE70970110 WAS REMOVED AND REPLACED AND PERFORMED LEAK CHECK IAW AMM 29-11-05, NO LEAKS WERE FOUND. (K)

QML2008F00013

BOLKMS

 

 

COMPUTER

FAULTED

9/13/2008

BK117A4

 

 

117884141

YAW

WHILE RETURNING TO BASE, CREW NOTICED AN INCREASING STRONG ELECTRICAL ODOR AS THE ACFT TURNED FINAL. CONTINUED TO THE LANDING AREA AND PUT THE ACFT OUT OF SERVICE. CREW SAW NO SMOKE BUT ONLY THE ODOR. MAINTENANCE FOUND YAW COMPUTER TO BE FAULTY AND REPLACED IT. NO CIRCUIT BREAKERS WERE DISPLACED AND LOAD METERS READ NORMAL THROUGHOUT THE EVENT. THERE WERE NO OTHER ABNORMALITIES OR DAMAGES. (K)

RMX2008F00003

BOLKMS

 

 

SKIN

DAMAGED

9/23/2008

BK117A4

 

 

1172250401

FUSELAGE

DURING A SCHEDULED INSPECTION, 3 AREAS OF THE PRIMARY FUSELAGE SKIN HAD CORROSION DAMAGE THAT WAS COMPLETELY THROUGH THE SKIN THICKNESS. DAMAGE AREA WAS APPROX 1 SQ INCH AT EACH DAMAGE LOCATION. THE AREAS WERE LOCATED AT : 1 EA AREA UNDER THE REFUELING GROUND CLIP LT FUSELAGE SKIN AT STA 5100MM, WL 1600MM. 2EA AREAS; ONE ON BOTH LT AND RT FUSELAGE SKINS AT THE AFT ENGINE COWLING LATCH PLATE. FUSELAGE STA 5800 MM, WL 2600 MM. (K)

RMX2008F00004

BOLKMS

 

 

SKIN

DAMAGED

9/23/2008

BK117A4

 

 

1172250402

FUSELAGE

DURING A SCHEDULED INSPECTION, 3 AREAS OF THE PRIMARY FUSELAGE SKIN HAD CORROSION DAMAGE THAT WAS COMPLETELY THROUGH THE SKIN THICKNESS. DAMAGE AREA WAS APPROX 1 SQ INCH AT EACH DAMAGE LOCATION. THE AREAS WERE LOCATED AT; 1 EA AREA UNDER THE REFUELING GROUND CLIP LT FUSELAGE SKIN AT STA 5100MM, WL 1600MM. 2 EA AREAS; ONE ON BOTH LT AND RT FUSELAGE SKINS AT THE AFT ENGINE COWLING LATCH PLATE. FUSELAGE STA 5800, WL2600MM. (K)

J7S2008F00001

BOMBDR

 

 

WHEEL

VIBRATION

9/9/2008

BD1001A10

 

 

 

NLG

CREW EXPERIENCED SEVERE VIBRATION FROM THE NOSE GEAR ON TAKEOFF ROLL. MULTIPLE CAS MESSAGES DISPLAYED, INCLUDING `AOA FAIL`. CAS MESSAGES CLEARED WHEN AIRCRAFT WAS SLOWED. PERFORMED A REJECTED TAKEOFF AND TAXIED BACK TO MAINTENANCE WITH NO ADDITIONAL PROBLEMS. MX PERFORMED DOWN LOAD FROM THE MDC AND REFERRED TO FIELD SERVICE. GAINED ACCESS TO THE MOISTURE TRAPS AND FOUND WATER INT THE STANDBY MOISTURE TRAP. CLEARED. RETORQUED NOSE WHEEL ASSEMBLIES AND GREASED NOSE GEAR ASSEMBLY. ALL OPERATIONAL CHECKS SATISFACTORY. (K)

NSV2008F00026

BOMBDR

 

 

CONDITION LEVER

MALFUNCTIONED

9/18/2008

DHC8402

 

 

 

 

DURING INITIAL CLIMB PEC NR 1 AND NR 2 CAUTION LIGHT ILLUMINATED AFTER INADVERTENT MOVEMENT OF CONDITION LEVERS PAST 850 MIN POSITION. CONDITION LEVERS IMMEDIATELY RESET TO 850, PROP RPM REMOVED STEADY AT 1060 THROUGH REMAINDER OF FLIGHT. RETRIEVED FADEC CODE IAW Q400-AMM 45-00-79-742-801 FAULT CODES SET NR1 FADEC 260, 236, NR 2 FADEC 280, 236 DETERMINED DUE TO CONDITION LEVERS DROPPED BELOW MIN 850. CLEARED FAULT CODES IAW Q400 AMM 45-00-73-743-801. POWERPLANT MESSAGE DEILLUMINATED. (K)

NSV2008F00025

BOMBDR

 

 

WHEEL

VIBRATION

9/8/2008

DHC8402

 

 

 

NLG

AIR RETURN, NOSE WHEEL VIBRATION ON TAKEOFF, DECLARED AN EMERGENCY. RETURNED TO FIELD, LANDED SAFELY. (K)

QXEA200801021

BOMBDR

 

 

SEQUENCE VALVE

MALFUNCTIONED

9/24/2008

DHC8402

 

 

 

NLG

NOSE LANDING GEAR DOORS DID NOT CYCLE CLOSED AFTER GEAR SELECTED DOWN. DID NOT EXCEED SPEED LIMITS. LANDING UNEVENTFUL. FERRIED FOR REPAIRS. REPLACED THE NLG SOLENOID SEQUENCE VALVE AND FLUSHED THE HYDRAULIC LINES. CHECKS GOOD. RETURNED TO SERVICE. (K)

QXEA200801020

BOMBDR

 

 

UNKNOWN

ODOR

9/23/2008

DHC8402

 

 

 

CARGO BAY

RAMP REPORTS ELECTRICAL SMELL IN AFT CARGO COMPARTMENT. MAINTENANCE PERFORMED GVI OF COMPARTMENT WITH NO DEFECTS NOTED. RAN APU AND BLEED AIR WITH NO SMELL NOTED. COULD NO DUPLICATE. RETURNED TO SERVICE. NO PARTS REPLACED. (K)

NSV2008F00021

BOMBDR

 

 

LOCK

MALFUNCTIONED

9/13/2008

DHC8402

 

 

 

NLG

NOSE GEAR DID NOT RETRACT IN FLIGHT. RESET GROUND LOCK IAW AMM 9-10-00, OPS CHECK GOOD. (K)

NSV2008F00027

BOMBDR

 

 

HANDLE

UNSECURE

9/16/2008

DHC8402

 

 

 

CARGO DOOR

ACFT RETURNED TO FIELD AFTER TAKEOFF. AFT CARGO DOOR LIGHT ILLUMINATED AFTER TAKEOFF. FOUND AFT CARGO DOOR HANDLE NOT PROPERLY SECURED. RESEATED DOOR AS REQUIRED. NO FURTHER ACTION REQUIRED AT THIS TIME. (K)

 

NSV2008F00029

BOMBDR

 

 

SEAL

LACK OF LUBE

9/27/2008

DHC8402

 

 

 

SERVICE DOOR

RT AFT SERVICE DOOR ILLUMINATED THE FUSELAGE DOORS LIGHT INFLIGHT. PERFORMED OPS CHECK AT RT AFT SERVICE DOOR IAW AMM 52-41-00-710-801. OPS CHECK GOOD. COULD NOT DUPLICATE FAULT. LUBRICATED DOOR SEALS IAW RIL 84-12-003. (K)

QXEA200801019

BOMBDR

 

 

EXCITER

FAILED

9/24/2008

DHC8402

 

 

4951070

APU

FLIGHT 2215. APU FAILED TO START, FLAME CAME OUT OF THE TAIL ON START ATTEMPT. PLACED THE APU ON MEL 49-00-1. CLEARED ON 9/28 BY REPLACING THE APU EXCITER AND IGNITER "B". OPERATIONAL CHECKS GOOD. RETURNED TO SERVICE. (K)

2008FA0000594

BRAERO

 

 

OXYGEN MASK

DAMAGED

8/11/2008

BAE125800A

 

 

MC1014101

CABIN

THREE OXYGEN MASKS WERE FOUND TO HAVE THE SAME FAULT. WHEN THE EMERGENCY/PRESS TO TEST CONTROL WAS TURNED TO EMERGENCY THERE WAS NOT A POSITIVE INCREASE IN PRESSURE. REF MFG MM 35-20-52, PAGE 502 TEST (13). PROBABLE CAUSE: UNKNOWN, RECOMMENDATION: INCREASE HOW OFTEN CREW OXYGEN MASKS ARE TESTED AND INSURE THAT THEY ARE BEING TESTED PROPERLY. (K)

2008FA0000593

BRAERO

 

 

OXYGEN MASK

FAILED

8/11/2008

BAE125800A

 

 

MC1014101

CABIN

THREE OXYGEN MASKS WERE FOUND TO HAVE THE SAME FAULT. WHEN THE EMERGENCY/PRESS TO TEST CONTROL WAS TURNED TO EMERGENCY THERE WAS NOT A POSITIVE INCREASE IN PRESSURE. REF MFG MM 35-20-52, PAGE 502 TEST (13). PROBABLE CAUSE: UNKNOWN, RECOMMENDATION: INCREASE HOW OFTEN CREW OXYGEN MASKS ARE TESTED AND INSURE THAT THEY ARE BEING TESTED PROPERLY.(K)

JLT2008F00000

BRAERO

 

 

PUMP

FAILED

7/18/2008

BAE125800A

 

 

307085057

NR 1 ENG FUEL

ON THE EVENING OF FRIDAY, JULY 18TH, ON CLIMB, EN ROUTE, THE CREW OBSERVED THE LT ENGINE, SN 91535, FUEL LIGHT ILLUMINATED. THE CREW REDUCED POWER. ENGINE THEN EXPERIENCED AN UNCOMMANDED INFLIGHT SHUTDOWN. CREW SECURED THE ENGINE AND ATTEMPTED A RESTART. RESTART WAS UNSUCCESSFUL. CREW THEN EXECUTED AN AIR TURNBACK AND SIGNALED AN EMERGENCY LANDING. TROUBLESHOOTING HAS REVEALED THAT THE FUEL PUMP FAILED A FUNCTIONAL CHECK. (K)

DGC2008F00002

BRAERO

GARRTT

 

LINE

CRACKED

9/12/2008

BAE125800A

TFE7315R

 

30753851

OILPRESSURE

AT CRUISE FLIGHT, AFTER 1 HR 27 MIN INTO FLIGHT, THE LT OIL PRESSURE INDICATOR FLUCTUATED FROM APPROXIMATELY 42-45 PSI DOWN TO 30-35 PSI TWICE PER SECOND CONTINUOUSLY. OIL TEMP REMAINED NORMAL, ALL OTHER ENGINE INDICATIONS NORMAL, (N1, ITT, N2). APPROXIMATELY 4-6 MINUTES LATER THE OIL PRESSURE INDICATOR FLUCTUATED DOWN TO 25-35 PSI, THE LT ENGINE "OIL PRESS LOW" ANNUCIATOR ILLUMINATED. THE SIC REDUCED POWER TO IDLE, EXECUTED SHUTDOWN PROCEDURES IAW CHECKLIST PROCEDURE. THE PIC DECLARED AN EMERGENCY AND DIVERTED . THE LT ENGINE OIL FILTER BYPASS INDICATOR WAS FOUND POPPED, METAL PIECES WERE FOUND IN THE FILTER AND TRANSFER GEARBOX, AND THE NR 6 BEARING, OIL PRESSURE LINE WAS FOUND CRACKED. (K)

2008FA0000596

CESSNA

CONT

 

MUFFLER

FAILED

8/21/2008

150H

O200A

 

83004

ENGINE

END CAP SEPARATED (CLEAR BREAK) FROM MUFFLER CAR. FAILURE OCCURED IN THE BEND RADIAS OF END CAP. NOT IN THE END CAP TO MUFFLER CAP, WELD. (K)

2008FA0000682

CESSNA

 

 

CONTROL CABLE

BROKEN

6/21/2008

170A

 

 

05701051

RUDDER

CABLE BROKE AFT OF REAR PULLEY AND BULKHEAD. NO INSPECTION HOLES IN THIS AREA. (K)

2008FA0000635

CESSNA

CONT

 

ENGINE

POWER LOSS

8/24/2008

172F

O300D

 

 

 

AC WAS NOT OPERATING UNDER PART 135, IT WAS UNDER PART 91 FLIGHT WHEN INCIDENT OCCURRED. PILOT STATEMENT "ENROUTE, AS WE CRESTED THEMOUNTAINS, THE ENGINE STARTED SPUTTERING, AND RPMS WERE DROPPING. APPLIED CARB HEAT, TRIED SWITCHING BETWEEN FUEL TANKS, MAGNETOS, AND THE RPMS KEPT DROPPING. WE THEN WENT THROUGH THE FORMAL CHECK LIST TO NO AVAIL. THE DECISION WAS MADE TO LAND AT RADAR FACILITY. BY THIS TIME THE ENGINE HAD STOPPED. WE MADE THE EMERGENCY LANDING AT THE FACILITY AND CAME TO A FULL STOP. DURING THE DESCENT, TRIED STARTING THE ENGINE MULTIPLE TIME, BUT IT DIDN’T START. NO ONE WAS INJURED AND THE PLANE WAS NOT DAMAGED.

2008FA0000713

CESSNA

LYC

 

SEAT FRAME

CRACKED

10/13/2004

172M

O320*

 

05140778

COCKPIT

DURING A ROUTINE 100 HOUR INSPECTION IT WAS DISCOVERED THAT THE PILOTS FULLY ADJUSTABLE SEAT FRAME WAS CRACKED IN SEVERAL PLACES. SOME AREAS WERE COVERED UP BY THE UPHOLSTERY WHICH IS GLUED TO THE FRAME IN THAT AREA. OTHER AREAS OF CONCERN WERE INCOMPLETE WELDS DONE AT THE FACTORY. (3) OUT OF (4) SUPPORT LEGS WERE CRACKED AT THE WELD AND AT THE ATTACHMENT POINT TO THE BOTTOM SEAT ASSY. (K)

2008FA0000605

CESSNA

LYC

 

WHEEL

FAILED

8/7/2008

172M

O320*

 

D30260

LT MLG

AFTER LANDING, WHILE TAXIING, HEARD A LOUD BANG. THEN ANOTHER BANG AND THE ACFT DROPPED LEFT. STOPPED, CONTACTED GROUND AND ASKED FOR ASSISTANCE. FOUND THE LT MAIN TIRE FLAT AND OUTER RIM FROM THE LT MAIN WHEEL WAS LYING 6 FT BEHIND ACFT, THE ATTACH BOLTS WERE SCATTERED ACROSS THE TAXIWAY. COULD ONLY FIND FOUR OF THE SIX BOLTS. ASI EXAMINATION OF THE WHEEL, THERE WAS A SPLIT IN THE INNER TUBE AND THE FOUR OUTER RIM ATTACH BOLTS THAT WERE FOUND HAD METAL FROM THE CENTER WHEEL HUB EMBEDDED IN THE BOLT THREADS WHERE THEY HAD PULLED OUT OF THE HUB. TWO BOLTS WERE NOT LOCATED. INSPECTED THE BOLT ATTACH AREAS OF THE HUB WITH A MAGNIFYING GLASS, FOUND SOME CORROSION BUT NO APPARENT CRACKS NOTED. IT APPEARS THAT EITHER THE BLOWN TUBE AND ACFT ROLLING ON FLAT TIRE PRESSED THE OUTER RIM BOLTS OUT OF THREADS, OR THE BOLTS WERE IMPROPERLY TORQUE AND RIM CAME OFF WHEN TUBE BLEW. THE LAST RECORDED ENTRY IN MAINT RECORDS FOR THE LT MAIN WHEEL THAT COULD BE FOUND WAS ON 1/17/2006 AT TACH TIME OF 2995.4 HOURS. THE ENTRY READ AS FOLLOWS: REPLACED LT MAIN TIRE AND BRAKE LININGS AND DISC. ACCORDING TO THE RECORDS THIS WAS OVER 2.5 YEARS AGO SINCE THIS WHEEL WAS APART, UNLESS UNDOCUMENTED MAINT HAS BEEN PERFORMED SINCE THAT TIME. STEEL BOLTS THREADED INTO A MAGNESIUM OR ALUMINUM HUB DOES NOT APPEAR TO BE A GOOD DESIGN, A THRU BOLTED WHEEL WITH LOCK NUTS ON THE BACK SIDE IS A MUCH BETTER METHOD FOR SECURING WHEEL HALVES. (K)

2008FA0000649

CESSNA

LYC

 

MAGNETO

SEIZED

9/22/2008

172P

O320D2J

 

7710398

LEFT

DURING FLIGHT, A SHUDDER AND SLIGHT LOSS OF POWER WAS REPORTED BY THE PILOT. PRIOR TO THE NEXT FLT DURING THE MAGNETO CHECK IT WAS DISCOVERED THAT THE LT MAGNETO WAS INOPERATIVE. FURTHER INVESTIGATION FOUND THE LT MAGNETO CONDENSER WAS OUT OF THE MAGNETO CASE AND THE MOUNT FLANGE WAS BROKEN. THE MAGNETO HAD SEIZED, CAUSING THE CASE TO BREAK FREE OF THE ENGINE. THE INTERNAL PARTS MELTED AND DESTROYED. INSP OF THE INSIDE OF THE ENGINE DRIVE GEARS AND CASE DID NOT REVEAL ANY DAMAGE. OIL WAS DRAINED AND INLET SCREEN CHECKED WITH NO METAL FOUND. THE MAGNETO WAS REPLACED. ACCORDING TO THE LOGBOOKS, THE REMOVED MAGNETO HAD BEEN OVERHAULED AND INSTALLED AT ENGINE OVERHAUL ON 6/30/08 WITH NO INDICATION OF FURTHER MAINTENANCE OR A 500 HOUR INSPECTION. (K)

2008FA0000583

CESSNA

LYC

 

CYLINDER HEAD

SEPARATED

7/8/2008

172RG

O360F1A6

 

 

ENGINE

ON JULY 8, 2008, MADE AN EMERGENCY LANDING IN DESSERT TERRAIN AFTER THE ENGINE BEGAN TO EXHIBIT SEVERE VIBRATIONS, LOSS OF POWER AND SMOKE. THE NR 2 CYLINDER WAS FOUND TO HAVE SEPARATED FROM THE CASE, SEVEN OF THE EIGHT HOLD STUDS WERE FOUND TO HAVE SHEARED. ONLY ONE HOLD DOWN STUD WAS LT INTACT. THERE WAS NO HISTORY IN THE AC LOGS TO INDICATE IF THE HOLD DOWN STUDS HAD BEEN REPLACED. (K)

2008FA0000601

CESSNA

 

 

STARTER

FAILED

9/1/2008

172S

 

 

149NL

ENGINE

STARTER MOTOR FAILURE, AFTER PRE-FLIGHT CHECK, THE STARTER MOTOR WAS UNABLE TO TURN THE ENGINE OVER. (K)

2008FA0000636

CESSNA

 

 

PIVOT ASSY

SHEARED

9/10/2008

177RG

 

 

20410202

MLG ACTUATOR

PILOT COULDN’T OBTAIN GEAR DOWN INDICATION AFTER EXTENDING GEAR. JACKED AC AND FOUND MAIN GEAR WOULDN’T COMPLETELY ENTER DOWN-AND-LOCKED POSITION. FOUND MAIN GEAR RETRACT ACTUATOR REAR MOUNTING/ PIVOT PIN HAD ONE SIDE COMPLETELY SHEARED. THIS ALLOWED/CAUSED THE TUBULAR MOUNT STRUCTURE TO FLEX FROM SIDE TO SIDE AND CRACK MOST OF THE WAY THROUGH. (K)

2008FA0000591

CESSNA

LYC

 

PISTON RING

MISMANUFACTURED

8/5/2008

177RG

IO360A1B6

 

ST203P010

ENGINE

ENGINE WAS OVERHAULED USING MFG PISTON RINGS ST203P010. AFTER 25.4 HRS, RINGS STILL NOT SEATED AND EXCESSIVE BLOW-BY WAS FOULING PLUGS. REPLACED WITH ANOTHER SET OF ST203P010 AFTER HAVING CYLINDERS REWORKED. AFTER 4.2 HRS, ENGINE WAS OPERATING SO POORLY, DUE TO BLOW-BY, THAT IT WAS CONSIDERED UNSAFE AND GROUNDED. INDEPENDENT HARDNESS TESTING BY QUALITY TESTING SVCS, INC, COMFIRMED THE RINGS WERE SOFT. COMPARATIVE TESTS WERE PERFORMED AGAINST PISTON RINGS. AFTER SWITCHING TO OTHER, THERE HAVE BEEN NO PROBLEMS.(K)

C2X2008F00049

CESSNA

RROYCE

 

ROTOR

ERODED

7/2/2008

182P

AE3007A1E

 

23074650

HP TURBINE

THE CREW REPORTED ENGINE NR 1 HP INDICATION IN YELLOW RANGE AFTER TAKEOFF, THE ACFT RETURNED TO DEPARTURE AND LANDED WITHOUT INCIDENT. MAINTENANCE INSPECTED AND REPLACED THE NR 1 ENGINE. OPERATIONAL CHECKS WERE GOOD. SUPPLEMENT TO FOLLOW: CONDITION REPORT FROM MFG INDICATED HOT SECTION DETERIORATED. THE HIGH PRESSURE TURBINE MODULE EXHIBITED SULFIDATION AND EROSION OF AIRFOILS AS WELL AS A CRACKED COMBUSTION LINER. THE 1ST STAGE HPT VANES EXHIBITED COATING LOSS ON THE AIRFOILS AND EROSION/CRACKING ON THE AIRFOIL TRAILING EDGES. (BURN-THROUGH) (K)

2008FA0000688

CESSNA

LYC

 

PUMP

CRACKED

10/1/2008

182S

IO540AB1A5

 

154739704

FUEL SYSTEM

PUMP HOUSING CRACKED ALONG SEAM. POSSIBLE WEAK SPOT UPON MANUFACTURING. (K)

2008FA0000612

CESSNA

 

 

BEARING

BURNED

9/3/2008

182T

 

 

 

MAGNETO

REMOVED MAGNETO TO S/B3-08 AND MFG 500 HOUR INSPECTION. REMOVED HARNESS CAP FOUND A LIGHT SMOKE COLORED FILM COVERING CAP AND DISTRIBUTOR BLOCK. REMOVED MAGNETO FROM ENGINE FOUND BEARING BAR BURNED THROUGH ON LEFT SIDE WHEN VIEWED FROM DRIVE END. (K)

2008FA0000602

CESSNA

PWA

 

OIL COOLER

CRACKED

8/14/2008

208

PT6A114

 

99103434

 

UPPER MOUNTING FLANGE HAS A 1.25 INCH CRACK AGAINST OIL COOLER BODY. (K)

2008FA0000657

CESSNA

PWA

 

COWLING

CRACKED

9/19/2008

208

PT6A114

 

265202231

EXHAUST

THE SECONDARY EXHAUST COWLING WAS FOUND TO HAVE A 5.5 INCH LONG CRACK NEXT TO THE CENTER EXHAUST HANGER ROD END BRACKET. (K)

2008FA0000708

CESSNA

 

 

LINE

FROZEN

9/24/2008

208B

 

 

 

DE-ICE SYSTEM

DURING MX OPERATION OF DE-ICE BOOTS MINUTES AFTER ACFT RETURNED FROM FLT, OPERATION OF THE DEICE BOOTS PRODUCED NORMAL COCKPIT INDICATION (GREEN PRESSURE LIGHT). NOTICED, THOUGH, THAT THE RT WING DEICE BOOTS DID NOT INFLATE DESPITE THE INFLATION INDICATION IN THE COCKPIT. FROZEN WATER WAS FOUND AT A BEND IN THE DEICE AIR SUPPLY DUCTING IN THE RT WING ROOT. THIS ALLOWED PRESSURE TO BUILD UP AND ACTIVATE THE PRESSURE SWITCH, PRODUCING A NORMAL INDICATION IN THE COCKPIT DESPITE THE BOOTS NOT ACTUALLY INFLATING. IF THIS WERE TO OCCUR IN THE TAIL, IT WOULD BE EVEN MORE UNDETECTABLE. RECOMMEND A CALIBRATED LEAK IN PNEUMATIC SUPPLY DUCTING IN THE FUSELAGE/ WING TO PREVENT THE ACCUMULATION OF WATER. (K)

COEA0801788

CESSNA

 

 

TRANSDUCER

FLUCTUATES

9/27/2008

208B

 

 

99103386

FUEL FLOW

UNSCHEDULED LANDING, WHILE ENROUTE, THE FUEL FLOW GAGE BEGAN TO FLUCTURATE BETWEEN 150 AND 300 PPH. THE PAR (POWER ANALYZING RECORDER) WAS ALSO SHOWING THE SAME FLUCTUATION. THE FUEL FLOW TRANSDUCER WAS REMOVED AND REPLACED. (K)

2008FA0000671

CESSNA

 

 

WIRE HARNESS

CHAFED

9/24/2008

208B

 

 

CC75LA61

FLAP SYSTEM

TIE WRAP WAS MISSING FROM THE CLAMP AT FS 201.50, WHICH ALLOWED THE WIRING BUNDLE CONTAINING THE WIRES FOR THE FLAP SYS PRIMARY MOTOR TO SAG AND CHAFE THROUGH WIRE NR CC75 TO THE FLAP SYSTEM AND PARTIALLY THROUGH LA61 TO THE CARGO AREA LIGHTS ON THE BULKHEAD. THIS CAUSED THE FLAPS TO ONLY RECEIVE POWER TO THE PRIMARY MOTOR IN ONE DIRECTION. SINCE WIRE LA61 WASN`T CHAFFED COMPLETELY THROUGH THE CARGO AREA LIGHTS WERE STILL WORKING. (K)

2008FA0000622

CESSNA

PWA

 

COWLING

CRACKED

9/4/2008

208B

PT6A114

 

265202231

EXHAUST

THE SECONDARY EXHAUST COWLING WAS FOUND TO HAVE A 5.5 INCH LONG CRACK NEXT TO THE CENTER EXHAUST HANGER ROD END BRACKET. IT WAS NOTICED THAT ANOTHER CARAVAN IN THE HANGER FOR INSPECTION HAD THE SAME CRACK (LENGTH AND LOCATION) THAT HAD BEEN PREVIOUSLY REPAIRED BY INSTALLING A DOUBLER PATCH. (K)

FPI2008F00001

CESSNA

CONT

 

CABLE

BROKEN

8/14/2008

210M

IO520*

 

505530401

NLG

MFG SERVICE KIT, PN SK210-174 CABLE ASSEMBLY BROKE AT THREADED END AFTER THE STOP NUT FIVE WEEKS AFTER INSTALLATION APPEARS THREAD WALL IS TOO THIN LEADING TO FATIGUE. (K)

2008FA0000623

CESSNA

 

 

SKIN

CRACKED

9/5/2008

310Q

 

 

 

LT WING

FOUND CRACK IN UPPER WING SKIN AS DESCRIBED IN SB MEB08-3. CRACK EXTENDS 4 INCHES FORE AND AFT PARALLEL TO LT WING MAIN LANDING GEAR ASIDE BRACE WING RIB NR 502210451 OB FLANGE. CRACK IS APPROXIMATELY CENTERED IN MLG WHEEL WELL OPENING. CRACK WAS FOUND VISUALLY DURING COMPLIANCE WITH MEB76-2 MAIN LANDING GEAR RIB SIDE BRACE CRACKS, DURING INSTALLATION OF SK414-8E. (K)

2008F00023

CESSNA

CONT

 

PUSHROD

FAILED

10/7/2004

402B

IO520*

 

 

ENGINE

ENGINE HAD MANIFOLD AND FUEL PRESSURE VARIATION IN FLT, THE ACFT BEGAN TO VIBRATE AND THE PILOT SHUTDOWN ENGINE. THE NR 1 AND NR 2 ROD`S FAILED AND SEPARATED FROM THE CRANKSHAFT AND CREATED (2) LARGE HOLES IN THE CASE AND KNOCKING BOTH MAGNETOS LOOSE. THERE ARE SIGNS OF OIL STARVATION ON THE CRANK AND OVERHEATING ASIGNS ON THE CRANKSHAFT. REMOVAL OF OTHER CYLINDERS INDICATED OIL STARVATION ON THE NR (6) AND (5) ROD`S ALSO. OVERHEATING OF THE CRANK AT THOSE LOCATIONS IS EVIDENT. PILOT VERIFIED LOSING OIL PRESSURE BEFORE SHUTTING THE ENGINE. (K)

XGN2008F00013

CESSNA

CONT

 

CYLINDER

CRACKED

9/29/2008

402B

TSIO520E

 

 

NR 1

CASE CRACKED, TOP OF NR 1 CYL, FWD TOP STUD 3 INCHES LONG. GOING UP TO TOP OF CASE. (K)

2008FA0000624

CESSNA

CONT

 

BUSHING

CRACKED

9/5/2008

414A

TSIO520NB

 

 

PISTON PIN

DURING CYLINDER NR 2 REMOVAL TO CORRECT CRACKED CYLINDER, FOUND CONNECTING ROD PISTON P/N BUSHING CRACKED WITH LARGE PIECE MISSING FROM EDGE. FAILURE IS AS NOTED IN MFG SB071. REMOVED ALL 6 CYLINDERS FROM ENGINE AND FOUND 4 MORE BUSHINGS CRACKED IN SAME LOCATION. MFG HAS CHANGED BUSHING SLIP LOCATION TO POSITION IAW FIGURE 3 OF SB B807. (K)

D382008F00000

CESSNA

CONT

 

THRU BOLT

BROKEN

 

8/29/2008

421A

GTSIO520C

 

ALB20AS1

RT ALT CASE HALF

 

22.2 HOURS AFTER INSTALLING AN OVERHAULED (ALV9510) ALTERNATOR, THE PILOT CAME TO ME ABOUT A THRU BOLT THAT WAS COMING OUT OF THE ALTERNATOR CASE. THERE WAS ONE THRU BOLT STICKING OUT OF THE CASE AND ANOTHER HAD COME OUT AND WAS GONE. THE ALTERNATOR WAS CHARGING THE ELECTRICAL SYSTEM AND THERE WERE FOUR THRU BOLTS STILL IN PLACE. ALSO, THE OIL SEAL APPEARED TO HAVE FAILED. THERE WAS SOME OIL NOTED INSIDE THE ALTERNATOR CASE. THERE WAS NO DAMAGE INCURRED BY THE AC AND WARRANTY REPLACEMENT ALTERNATOR WAS INSTALLED. (K)

 

2008FA0000625

CESSNA

CONT

 

BUSHING

CRACKED

 

9/5/2008

421C

GTSIO520N

 

 

PISTON PIN

 

DURING CYLINDER NR 5 REMOVAL TO CORRECT HIGH OIL CONSUMPTION , FOUND CONNECTING ROD PISTON PIN BUSHING CRACKED WITH LARGE PIECE MISSING FROM EDGE. FAILURE IS AS NOTED IN MFG SB SB07-1. REMOVED ALL 6 CYLINDERS FROM ENGINE AND FOUND 4 MORE BUSHINGS CRACKED IN SAME LOCATION. MFG HAS CHANGED BUSHING SLIP LOCATION TO POSITION IAW FIGURE 3 OF SB SB071. (K)

 

26N2008F00003

CESSNA

 

 

CONTROL CABLE

FROZEN

 

9/29/2008

510

 

 

70611107

AILERONS

 

ON CLIMB OUT, AT 20,000 FT THE AILERONS FROZE WITH AN OAT OF 0 DEGREES C. PILOT WAS GETTING THE AMBER AP LIGHT. HE WOULD TURN THE AP "OFF" AND FREE UP THE CONTROLS ABOUT EVERY 15 TO 20 MINUTES BY EXERTING A LOSS OF FORCE TO FREE THE ICING. AT 33,000 FT WITH AN OAT OF -22 DEGREES, AND THE AP ENGAGED, THE ELEVATOR FROZE. PILOT SAID IT TOOK AN UNBELIEVABLE AMOUNT OF FORCE TO GET THE AC TO RESPOND. JUST LIKE BEFORE, HE WAS CONTROLLING THE AC WITH ENGINES AND TRIM. AT 6,000 FT, ON APPROACH, HE WAS USING ELEVATOR TRIM TO CONTROL THE AC AND ALMOST MAX'D IT OUT. AC IS AT SERVICE CENTER AND ARE LOOKING FOR THE POSSIBLE CAUSES OF THE FREEZING. WE ARE FOCUSING ON WATER INTRUDING THE TAILCONE AND GETTING ON THE AILERON AND ELEVATOR PULLEYS THUS CAUSING THE FREEZE.

 

26N2008F00004

CESSNA

 

 

SELECTOR

FROZEN

 

9/29/2008

510

 

 

70611107

AILERONS

 

ACFT FLIGHT CONTROLS FROZE AT ALTITUDE ENROUTE. THIS IS THE SECOND SITUATION WHERE THIS CONDITION HAS HAPPENED TO THIS ACFT. ACFT PREVIOUS REGISTRATION N1693L. A TECH WAS WITH THE ACFT. INSPECTED AREAS OF PREVIOUS CONCERN AND SERVICE PREVIOUSLY WORKED BY MFG, DRIED AFFECTED AREA AND ACFT REPOSITIONED FOR EVALUATION AND RESOLUTION. (K)

 

26N2008F00005

CESSNA

 

 

SELECTOR

UNKNOWN

 

8/4/2008

510

 

 

70611107

AILERONS

 

CREW REPORTED AILERONS FROZE AFTER FLYING THROUGH MOISTURE. 07/25/2008 AC REPOSITIONED TO SERVICE CENTER FOR FURTHER EVALUATION AND RESOLUTION. MFG HEAVILY INVOLVED WITH THIS ISSUE. (K)

 

2008FA0000705

CESSNA

 

 

LINE

RUPTURED

 

9/29/2008

525

 

 

6317003136

HYDRAULIC SYS

 

RUPTURE OF TUBE AT SIDE WHERE BENDING DIES LEFT MARKING, BOTH ABOVE AND BELOW OPENING. AFTER TAKEOFF, LOW FLUID AND PRESSURE WARNING LIGHTS CAME ON AND ACFT RETURNED TO DEPARTURE. ACFT WAS TURNED OVER TO REPAIR STATION. LEAK WAS LOCATED AND LINE REPLACED ALONG WITH BOTH HYDRAULIC PUMPS. (K)

 

AJC2008F00001

CESSNA

 

 

SMOKE DETECTOR

FALSE ACTIVATION

 

9/14/2008

525

 

 

 

CARGO BAY

 

IN THE DESCENT FROM ALTITUDE FL430, THE BAGGAGE SMOKE LIGHT ILLUMINATED (RED). ACTION TAKEN BY CAPTAIN WAS REQUEST FOR PRIORITY HANDLING TO A SAFE LANDING IN MINUTES WITHOUT INCIDENT. PERFORMED VISUAL INSPECTION OF THE FWD AND AFT BAGGAGE COMPARTMENTS FOUND NO EVIDENCE OF SMOKE OR FIRE PRESENT. THIS IS A KNOWN ISSUE WITH MFG. THE FWD COMPARTMENT IS PRONE TO CONDENSATION WHICH TRIGGERS A BAGGAGE SMOKE ALERT. PREFORMED A BAGGAGE COMPARTMENT FIRE DETECTION TEST, SYSTEM TESTS NORMAL. (K)

 

2008FA0000686

CESSNA

 

 

LINE

RUPTURED

 

9/29/2008

525

 

 

6317003136

HYD SYSTEM

 

RUPTURE OF TUBE AT SIDE WHERE BENDING DIES LT MARKING BOTH ABOVE AND BELOW OPENING. AFTER TAKEOFF, LOW FLUID AND PRESSURE WARNING LIGHTS CAME ON AND ACFT RETURNED TO AIRPORT. ACFT WAS TURNED OVER TO SERVICE CENTER. LEAK WAS LOCATED AND THE LINE REPLACED ALONG WITH BOTH HYDRAULIC PUMPS. (K)

 

2008FA0000606

CESSNA

WILINT

 

FORK

BROKEN

 

8/15/2008

525

FJ44

 

63420003

NLG

 

DURING ROUTINE TAXI TO PERFORM MAINT CHECKS AFTER AC HAD BEEN PAINTED, NOSE GEAR AXLE BROKE LOOSE FROM NOSE GEAR STRUT. INVESTIGATION SHOWED BOTH WHEEL BEARING HAD HEAVY RUST AND DID NOT TURN FREELY ON THE AXLE. VERY LITTLE GREASE WAS FOUND IN EIGHER OF THE NOSE WHEEL BEARINGS. IT APPEARS THAT DURING THE TAXI, THE BEARINGS SEIZED ON THE AXLE AND THE RESULTANT STRESS AND HEAT CAUSED ONE SIDE OF THE NOSE STRUT ASSY TO BREAK WHICH IN TURN ALLOWED THE NOSE WHEEL AND AXLE TO COCK AND BEND THE OTHER SIDE OF THE NOSE STRUT. IMPROPER LUBRICATION OF THE NOSE WHEEL BEARINGS IS SUSPECTED AS A PROBABLE CAUSE. (K)

 

2008FA0000600

CESSNA

WILINT

 

BRAKE ASSY

MALFUNCTIONED

 

7/2/2008

525B

FJ44

 

 

MLG

 

NORMAL LANDING UNTIL BRAKE APPLICATION, AT BRAKE APPLICATION AC YAWED AGRESSIVELY TO THE LT. AC WAS CONTROLLED WITH RT BRAKE AND NOSE WHEEL STEERING. RT BRAKE APPEARED WEAK, AS SPEED DECREASED DIRECTION CONTROL WAS HARDER TO MAINTAIN. AC DECELERATED SLOWER THAN NORMAL APPROACHING END OF RUNWAY. EMERGENCY BRAKE WAS APPLIED. LT BRAKE GRABBED FORCING THE ACFT OFF THE RUNWAY INVESTIGATION IN TO SOURCE OF THE PROBLEM IS ON GOING. PN AND PART NAME WILL FOLLOW AFTER MFG TEST COMPONENTS. (K)

 

Z5F2008F00004

CESSNA

 

 

BRAKE

WORN

 

8/28/2008

550