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

400

bald eagle watching over three eggs

NOVEMBER

2011

 


CONTENTS

AIRPLANES

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

CESSNA...................................................................................................................................... 4

ZENAIR....................................................................................................................................... 9

HELICOPTERS

EUROCOPTER.......................................................................................................................... 13

POWERPLANTS

LYCOMING.............................................................................................................................. 16

ACCESSORIES

TCM MAGNETO...................................................................................................................... 21

AIR NOTES

INTERNET SERVICE DIFFICULTY REPORTING (iSDR) WEB SITE................................... 22

IF YOU WANT TO CONTACT US......................................................................................... 24

AVIATION SERVICE DIFFICULTY REPORTS...................................................................... 24

 


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

AVIATION MAINTENANCE ALERTS

The Aviation Maintenance Alerts provides the aviation community with an economical means to exchange service experiences and to assist the FAA in improving aeronautical product durability, reliability, and safety.  We prepare this publication from information operators and maintenance personnel who maintain civil aeronautical products pertaining to significant events or items of interest.  At the time we prepared this document, we have not fully evaluated the material.  As we identify additional facts such as cause and corrective action, we may publish additional data in subsequent issues of the Alerts.  This procedure gives Alerts’ readers prompt notice of conditions reported to the FAA Service Difficulty Reporting System (SDRS).  We welcome your participation, comments, and suggestions for improvement.  Send to:  FAA; ATTN: Aviation Data Systems Branch (AFS-620); P.O. Box 25082; Oklahoma City, OK 73125-5029.

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

 

AIRPLANES

Beechcraft:  200; Cracked Spar Attach Fitting; ATA 5740

A general aviation submitter states, "While accomplishing a wing bolt inspection, the L/H lower wing spar attach shear fitting was found cracked (P/N 1011100731).  This crack is approximately 0.75 inches long—located in the forward flange area."

CATALOGUE DRAWING OF SPAR FITTING.


PHOTO OF CRACKED PART.


CLOSEUP PHOTO OF CRACKED PART.

Part Total Time:  13,141.0 hours

 


Cessna:  Cracked Main Landing Gear Casting; ATA 5343

"The (main landing gear attach) casting crack was found by visual inspection," says the repair station technician.  "The crack is located on the forward end of the support casting, and (starts) 0.25 inches from the mount holes on the outboard side (and extends) to within 0.25 inches of the mount holes on the inboard side of the casting (P/N 07416031)."

PHOTO OF CASTING (VIEW 1).

PHOTO OF CASTING (VIEW 2).


(No part numbers were provided with this report—Ed.)

Part Total Time:  2,690 hours

 

Cessna:  560; Flap Pulley Brackets Missing Rivets; ATA 5320

A repair station mechanic states, "Three each rivets were found missing from the upper and lower flap interconnect pulley brackets (P/N's 6565059-5 and 6565059-3) at fuselage station 354.00.  (These) rivets were found missing while performing an under-floor inspection—presumably omitted during production."

PHOTO OF OPENED CABIN FLOOR.


CLOSEUP PHOTO OF MISSING RIVETS IN FIRST PART.


CLOSEUP PHOTO OF MISSING RIVETS IN SECOND PART.

Part Total Time:  2,001.3 hours

 

Cessna:  560XLS; Loose Elevator Push-pull Tubes; ATA 2730

"(Note:  the location of this defect...) is the rear of the aircraft in the compartment below the horizontal stabilizer attach point," says this repair station technician.  "Two push-pull tubes that attach to the aft elevator bell crank (have nuts) that shank-out on the bolt.  This allows the bolts to be rotated by hand, causing wear in the bell crank attach hole."  "(Now) the bolt begins to rock back and forth in the hole, resulting in chafing between the attached parts.

"Recommendation:  When installing hardware, assure the nut does not shank-out on the bolt.  Replace the bolt if worn, and add washers as required to prevent the nut from (bottoming on the bolt's shank)."


TWO VIEWS OF PUSH-PULL TUBE.

Part Total Time:  2,347.0 hours

 


Zenair:  CH2000 (series); Nose Landing Gear Cracks; ATA (N/A)

(Transport Canada provides the following Safety Alert.)

TRANSPORT CANADA CIVIL SAFETY ALERT


TRANSPORT CANADA CIVIL SAFETY ALERT.


TRANSPORT CANADA CIVIL SAFETY ALERT.


TRANSPORT CANADA CIVIL SAFETY ALERT.

Part Total Time:  (N/A)

 


HELICOPTERS

Eurocopter:  SA365N3; Improper Safety on Rotor Shaft; ATA 6320

"The incorrect application of locking washers on the Rotor Shaft Nut retainer lock (P/N 117-12118-01) occurred during installation of the replacement Rotor Shaft," says this technician.  It was discovered while performing Main Gearbox lower casing repair (removal of the rotor shaft is required)."  (Lock washer P/N: LN9023B5-145449.)

 

PHOTO SHOWING INCORRECT WASHER APPLICATION.


PHOTO SHOWING CORRECT WASHER APPLICATION.

Part Total Time:  94.1 hours

 

Eurocopter:  SA365N3; Failed Pinion Roller Bearing; ATA 6520

A mechanic states, "Failure of the Input Pinion Tapered Roller bearing (in the Tail Rotor Gearbox) occurred during ground run after maintenance.  This gearbox is discolored due to overheating of the failed (seized) bearing."  (Bearing P/N:  704A33-652-044; Gearbox P/N:  365A33-6005-08.)


PHOTO SHOWING GEARBOX DISCOLORATION.
PHOTO SHOWING FAILED BEARING.

Part Total Time:  0.0 hours

 


POWERPLANTS

Lycoming:  LTIO540-J2BD; Failed Turbocharger; ATA 8120

An air carrier submissions says, "After landing touch-down, smoke was noticed exiting the rear of the R/H engine."  "The turbocharger's main bearing (had failed), allowing the impeller to hit the housing, causing it to loose blades.  Oil was able to get through the seals on the compressor (extremely hot turbine side), causing the fire and smoke.  There was no external fire in the engine compartment.  (Existing) fire was contained within the exhaust system, (allowing for) no visible fire damage...when the engine was inspected."  (Turbocharger P/N: LW12463W.)

TURBOCHARGER HOUSING (VIEW 1).


TURBOCHARGER HOUSING (VIEW 2).

TURBOCHARGER IMPELLER (VIEW 1).


TURBOCHARGER IMPELLER (VIEW 2).

Part Total Time: 1,685.0 hours

 

Lycoming:  TIO540-AE2A; Cracked Oil Baffle; ATA 8550

"This baffle (P/N LW-13383) has been replaced by a second (P/N 56G23399) and a third (P/N 56G26069)," states this mechanic.  "During the first 50 hour inspection, the suction oil screen was removed for condition inspection.  (I) found the head of a steel rivet in the screen.  I consulted the parts catalogue figure 23 (for the broken rivet's possible original location) and found baffle (item 1) to have a rivet assembly.  I then removed the oil sump and induction housing."  "The oil baffle had one rivet head missing, and I noted three of the six attaching holes had circular cracks emanating from under the washers.  After removal of all the attaching bolts and washers, it was noted all (housing) attaching (points) had been (scored) by the sharp edges of the washers."


CATALOGUE DRAWING OF OIL SUMP.


PHOTO OF BAFFLE SHOWING CRACKS.

(This part number reflects 12 entries in the SDRS database.)

Part Total Time:  83.5 hours

 


ACCESSORIES

TCM Magneto:  S6LN-1209; Loose Distributor Gear; ATA 7414

A mechanic says, "The pilot reported the R/H magneto failure.  (This unit) was inspected for security of attachment and correct timing to the engine."  "The magneto (P/N BL-349310-1) was removed and disassembled.  Upon inspection, the brass (or brass appearing...) metal shavings (were observed) under the distributor cap and near the gear.  The distributor gear was loose in the bearing— allowing the (rotor) to contact the ignition studs (four of six), wearing them down excessively.  This caused the gaps to be excessive, (resulting) in the magneto failing to produce spark.  We were informed only 60 hours (and 11 months) of service had (accumulated) on this magneto.  This unit is a remanufactured magneto.  No other damage was observed."  "A replacement unit was installed and operationally tested without defect."

PHOTO OF MAGNETO.


CLOSEUP PHOTO OF WORN DISTRIBUTOR BUSHING/SHAFT.

(Note:  the submitter says these photos were sent by I-phone!  Ed.)

Part Total Time:  60.0 hours

 

AIR NOTES

INTERNET SERVICE DIFFICULTY REPORTING (iSDR) WEB SITE

The Federal Aviation Administration (FAA) Internet Service Difficulty Reporting (iSDR) web site is the front-end for the Service Difficulty Reporting System (SDRS) database that is maintained by the Aviation Data Systems Branch, AFS-620, in Oklahoma City, Oklahoma. The iSDR web site supports the Flight Standards Service (AFS), Service Difficulty Program by providing the aviation community with a voluntary and electronic means to conveniently submit in-service reports of failures, malfunctions, or defects on aeronautical products. The objective of the Service Difficulty Program is to achieve prompt correction of conditions adversely affecting continued airworthiness of aeronautical products. To accomplish this, Malfunction or Defect Reports (M or Ds) or Service Difficulty Reports (SDRs) as they are commonly called, are collected, converted into a common SDR format, stored, and made available to the appropriate segments of the FAA, the aviation community, and the general public for review and analysis. SDR data is accessible through the “Query SDR data” feature on the iSDR web site at: http://av-info.faa.gov/sdrx/Query.aspx.

 


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

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

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

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

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

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

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

The SDRS and iSDR web site point of contact is:

Pennie Thompson
Service Difficulty Reporting System, Program Manager
Aviation Data Systems Branch, AFS-620
P.O. Box 25082
Oklahoma City, OK 73125
Telephone: (405) 954-5313
SDRS Program Manager e-mail address: 9‑AMC‑SDR‑ProgMgr@faa.gov

 


IF YOU WANT TO CONTACT US

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

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

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

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

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

 

AVIATION SERVICE DIFFICULTY REPORTS

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

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

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

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


Federal Aviation Administration

Service Difficulty Report Data

 

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

Control Number

Aircraft Make

Engine Make

Component Make

Part Name

Part Condition

Difficulty Date

Aircraft Model

Engine Model

Component Model

Part Number

Part Location

CHIR20110829001

 

 

 

SERVO VALVE

LEAKING

8/29/2011

 

 

 

114HS5801

NR 2 ROLL

HEADS MISSING ON 2 OF 4 CAP SCREWS ON TORQUE MOTOR DUST COVER DUE TO APPARENT LEAK AT TORQUE MOTOR/SERVO VALVE JOINT. NO APPARENT TORQUE MOTOR/SEALING SURFACE OR O-RING DAMAGE OBSERVED UPON DISSASSEMBLY--UNIT TESTED NORMALLY.

2011FA0000564

 

 

 

FLOAT

WORN

8/10/2011

 

 

 

AV30768

CARBURETOR

BRASS FLOATS, PN AV30-768 WITH PN 29-182 TYPE NEEDLE RETRACTION CLIPS HAVE BEEN FOUND WITH SEVERE WEAR IN THE FLOAT FRAME CAUSED BY THE END OF THE 29-182 TYPE CLIP WORKING AGAINST THE BRASS FLOAT FRAME. THESE FLOATS AND CLIPS WERE FOUND IN HA-6 CARBURETORS ORIGINALLY MADE. THE 29-182 TYPE CLIP IS INTENDED FOR USE WITH FLOAT FRAMES MADE OF STAINLESS STEELE. THE BRASS FLOATS EQUIPPED WITH THE 29-182 TYPE CLIPS APPEAR TO HAVE HAD THE BRACKET, PN 178-48, REMOVED TO WHICH THE PROPER WIRE FORM NEEDLE RETRACTION CLIP PN 29-194 ATTAHCES. EXCESSIVE WEAR OF THE FLOAT FRAME COULD RESULT IN THE FLOAT SYS STICKING AND COULD RESULT IN FUEL FLOW TO THE ENGINE BEING INTERRUPTED OR RESTRICTED. PN 29-182 FLOAT CLIPS ARE NOT APPROVED BY THE CARBURETOR MFG FOR USE WITH BRASS FLOAT FRAMES. SUBMITTER RECOMMENDS THAT CLIP TYPE 29-182 NEVER BE USED WITH BRASS TYPE FLOATS.

CA110126003

 

 

 

CONTROL UNIT

MISOVERHAULED

1/25/2011

 

 

 

 

SPOILERS

INSTALLED 13 HRS, 16 CYCLES, FLIGHT SPOILERS CAUTION MESSAGE AT GATE UNIT. R & R AT ACFT IAW AMM AND UNIT RETURNED TO MFG FOR REPAIR. UPON INVESTIGATION THAT THERE ARE SUSPECTED UNAPPROVED PARTS AND INCORRECT SOFTWARE INSTALLED ON THE CIRCUIT CARDS. INCOMING INSPECTION OF THE SPOILER ELECTRONIC CONTROL UNIT HAS REVEALED THAT QUALITY CONTROL INSPECTION, SEALS WERE BROKEN AND COMPONENTS FITTED ON 2 DIFFERENT ASSEMBLIES WERE NOT APPROVED OR SPECIFIED BY THE ORIGINAL MFG FOR THIS EQUIPMENT. ASSEMBLIES: -NTERFACE ASSEMBLY PN 7743-00258-01, SN 02193 PARTS AFFECTED: PROGRAMMABLE LOGIC DEVICE U1 & U101 ARE NOT AS SPECIFIED IN CMM AND ARE LABELLED RJHC INSTEAD OF RJNN (INCORRECT HARDWARE AND SOFTWARE INSTALLED FOR THE CONFIGURATION OF THE UNIT) -OUTPUT COMMON ASSY, PN 7743-00272-02, SN 02130, PARTS AFFECTED: FUSE F2 & F3 ARE NOT AS SPECIFIED IN THE OEM CMM. A SUSPECTED UNAPPROVED PARTS REPORT WILL BE FILED WITH THE FAA.

CA110512005

 

 

 

YOKE

WORN

2/19/2011

 

 

 

 

PROPELLER

PROP LEAKING OIL, REPLACED PROP ACTUATOR. TEAR DOWN REPORT INDICATES CHROME WORN ON YOKE INSIDE DIAMETER AND EARS.

CA110526008

 

 

 

DISPLAY

MISOVERHAULED

5/26/2011

 

 

 

100601702002

 

RECENTLY RECEIVED A MCDU FOR REPAIR. WHILE CONDUCTING MX, NOTED THAT DURING A PREVIOUS REPAIR THAT SOMEONE HAD REPLACED A FUSE F1 ON THE 28 VOLT INPUT LINE OF THE LIGHTNING PROTECTION CIRCUIT BOARD WITH A SOLID WIRE. THE PRODUCT IS BEING REPAIRED AND BROUGHT BACK TO CONFORMITY AND DWG SPECIFICATION. NOTE: ADDED MAY 27 BY PRM: SUBSEQUENT EXPLANATION RECEIVED FROM AIRLINE, EXPLANING THAT THE CONDITION DETECTED WAS INDUCED DURING TROUBLESHOOTING PRIOR TO RETURNING THE UNIT TO CMC FOR REPAIR.

CA110620001

 

 

 

HUB   

CRACKED

6/20/2011

 

 

 

D65211

PROPELLER

PROPELLER HAD A .2500" CRACK WAS FOUND FROM A BALANCE WEIGHT SCREW HOLE.

CA110620002

 

 

 

WIRE

BROKEN

6/14/2011

 

 

 

SMR22931

PROP DE ICE

DE-ICE HARNESS WIRES FOUND BROKEN.

CA110620003

 

 

HARTZL

PLUG

DISLODGED

6/20/2011

 

 

 

 

PROP GOVERNOR

GOVERNOR LEAKING OIL. FOUND THE PLUG FOR THE PRESSURE RELIEF VALVE WAS HANGING BY PIECE OF LOCK WIRE AND THE THREADS WERE STRIPPED.

FCPA201108230008

 

 

 

HUB   

GOUGED

8/23/2011

 

 

 

 

PROPELLER

PROPELLER IN SHOP FOR LEAKING OIL. UPON DISASSEMBLY, FOUND CYLINDER MOUNT SURFACE ON HUB GOUGED. NO DAMAGE OR REPAIR PERMITTED IN THIS AREA IAW SPM 100, 61-11-02. PROPELLER BLADES, PN 93KB-0, SN'S: BC164, BC039 AND K79615 ALL SCRATCHED ON BLADE SHANKS AT SECTION D-E. NO SCRATCHES, CORROSION OR REPAIRS ALLOWED IN THIS AREA IAW SPM 61-10-02. THIS PROPELLER AFFECTED BY NE-09-48 DATED AUG. 14, 2009.

FCPA201108250009

 

 

 

HUB   

GOUGED

8/25/2011

 

 

 

 

PROPELLER

PROPELLER DISASSEMBLED FOR INSPECTION IAW CUSTOMER REQUEST. UPON DISASSEMBLY, FOUND CYLINDER MOUNT SURFACE ON HUB GOUGED. NO DAMAGE OR REPAIRS ALLOWED IN THIS AREA IAW MFG SPM 100. 61-11-02. PROPELLER BLADES PN:93KB-0, S/N: BE027, BE119 AND BE125 ALL SCRATCHED ON BLADE SHANKS AT SECTION D-E. NO SCRATCHES, CORROSION OR REPAIRS ALLOWED IN THIS AREA IAW , MFG SPM 61-10-02. THIS PROPELLER AFFECTED BY NE-09-48 DATED AUG. 14,2009.

3HCR20110902001

 

ALLSN

 

FUEL CONTROL

FAILED

9/2/2011

 

250C30

 

2549092723070613

FUEL CONTROL

FUEL CONTROL BENCH CHECKED. FOUND CUT-OFF IMPROPERLY WORKING DURING TEST.

CA110624005

 

GE   

 

NUT   

MISINSTALLED

6/23/2011

 

CF343B1

 

3020T63P10

HP TURBINE DISK

SCHEDULED HEAVY MX WAS BEING PERFORMED ENGINE. DURING SEPARATION OF THE STAGE 1 AND 2 HIGH PRESSURE TURBINE DISKS, ONE RETAINING STUDS WAS HEARD TO UNSEAT AND FALL ONTO THE STAGE 2 DISK. WHEN THE 2 DISKS WERE SEPARATED, THE NUT WAS EVALUATED AND WITNESS MARKS ON THE NUT-THREADS INDICATED THAT ONLY ONE THREAD WAS RETAINING ON THE THE STUD.

2011FA0000565

 

LYC   

 

FITTING

MISINSTALLED

8/10/2011

 

O290*

 

 

CARBURETOR

THIS CARBURETOR WAS SENT IN FOR FUEL FLOW TEST BY THE CUSTOMER. UPON INSP OF THE CARBURETOR, THE TECH FOUND THAT THREAD SEALANT HAD BEEN APPLIED TO THE FUEL INLET FITTING. AS STATED IN SB-10 "THREAD SEALANT CAN BREAK AWAY INSIDE A CARBURETOR, CLOG FUEL PASSAGES, AND RESULT IN PARTIAL OR COMPLETE LOSS OF ENGINE POWER. A PREVIOUS SB A1-659 AND AD 69-24-03, DEALT WITH A SIMILAR ISSUE WHERE IN THREAD LUBRICANT WAS DISCOVERED IN CARBURETORS. SUBMITTER RECOMMENDS FOLLOWING THE INSTRUCTIONS CONTAINED IN THE APPROPRIATE CARBURETOR O/H MANUAL AS WELL AS OTHER APPLICABLE SERVICE INFO.

CA110617001

 

PWA   

 

BEARING CAGE

CRACKED

6/16/2011

 

JT15D5

 

310749301

NR 3 BEARING

ENGINEERING INVESTIGATION REPORT. CONFIRMED THAT ENGINE DID HAVE METAL CONTAMINATION OF THE OIL SYS. THE SOURCE OF METAL CONTAMINATION WAS THE NR 3 BEARING (PN 3107493-01, S/N FC153527) WHICH HAD A THROUGH GOING CRACK ON THE ROLLER CAGE. THE CRACK ALLOWED THE CAGE TO EXPAND AND THE ADJACENT ROLLER ELEMENT TO TURN SIDEWAYS WITHIN THE POCKET RESULTING IN HEAVY SCORES/GOUGES THE OUTER RACE. THE REASON WHY THE CAGE ON THE BEARING CRACKED COULD NOT BE DETERMINED.

CA110615003

 

PWA   

 

BEARING CAGE

CRACKED

6/14/2011

 

JT15D5

 

310749301

NR 3 BEARING

DURING EIR JT15D 2011-006, WAS ABLE TO CONFIRM THAT ENGINE DID HAVE METAL CONTAMINATION OF THE OIL SYS. THE SOURCE OF METAL CONTAMINATION WAS THE NR 3 BEARING WHICH HAD A CRACK ON CAGE WHICH ALLOWED THE ADJACENT ROLLER ELEMENT TO TURN SIDEWAYS WITHIN THE POCKET AND HEAVILY SCORED & GOUGED THE OUTER RACE. THE REASON WHY THE CAGE ON THE BEARING CRACKED COULD NOT BE DETERMINED.

CA110609001

 

PWA   

 

BLADE

FAILED

6/6/2011

 

PT6A28

 

 

ENGINE

EIR PT6A 2011-051 CONFIRMED INTERNAL ENGINE FAILURE. THE INTERNAL ENGINE FAILURE WAS CAUSED BY A CT BLADE FAILURE. THE BLADE FAILED AT THE LAST FIRTREE SERRATION CAUSING HEAVY IMPACT DAMAGE OF THE SHROUD AND ITS HSG AND ALSO CAUSING HEAVY IMPACT DAMAGE OF THE REMAINING CT BLADES. THE LIBERATED PARTS FURTHER DAMAGED THE DOWNSTREAM PT VANE, T5 PROBES AND PT BLADES. THE LIBERATION OF THE CT BLADE ALSO CAUSED COMPRESSOR TO BECOME OUT OF BALANCE CAUSING RUBBING DAMAGE OF THE IMPELLER, SPACERS AND AIRSEALS WITH THEIR MATING PARTS. THE FACT THAT THE FAILED BLADE WAS BROKEN AT THE FIRTREE IN THE RADIUS MAY INDICATE THAT THE CAUSE OF THE FAILURE WAS A CRACK IN THE FIRTREE AREA. THE CT VANE AND THE SMALL EXIT DUCT BURNING DAMAGE IS MOST LIKELY RESULT OF THE FAULTY FUEL NOZZLE. THE FUEL NOZZLE FAULTY FUEL SPRAY CREATED A HOT SPOT IN THE HOT SECTION DAMAGING THE SMALL EXIT DUCT AND THE CT VANE. THE BURNED CT VANE AIRFOIL EXPOSED THE CT BLADES TO THE DIRECT AXIAL AIRFLOW WHICH PROBABLY AFFECTED THE TURBINE EFFICIENCY AND THE BLADE AIRFOILS HEAT EXPOSURE. IT IS POSSIBLE THAT THIS CONDITION CONTRIBUTED TO THE BLADE FAILURE.

CA110615009

 

PWA   

 

SUN GEAR

CHIPPED

6/9/2011

 

PT6A41

 

3028456

ENGINE

OPERATOR REPORTED METAL CONTAMINATION IN THE ENGINE OIL SYS. ACCESS OF THE FIRST STAGE GEAR TRAIN REVEALED THAT THE MAJORITY OF ONE GEAR TOOTH WAS MISSING FROM THE FIRST STAGE SUN GEAR. SEVERAL OTHER FIRST STAGE SUN GEAR TEETH HAD SIGNIFICANT GEAR TOOTH DAMAGE. VISUAL INSPECTION OF THE FIRST STAGE PLANET GEARS REVEALED SOME SECONDARY IMPACT DAMAGE AND DENTING. 1 OF THE 3 GEARS, HAD A PIECE OF EMBEDDED MATERIAL ON ONE GEAR TOOTH THAT APPEARED TO BE A SMALL PIECE OF THE FIRST STAGE SUN GEAR. THE FIRST STAGE RING GEAR HAD ONE GEAR TOOTH THAT WAS CHIPPED AND MISSING MATERIAL.

CA110516016

 

PWA   

 

GASKET

LEAKING

5/9/2011

 

PT6A64

 

 

ENGINE OIL SYS

(CAN) OIL LEAK 5 MILES OUT, THE ENGINE HAD A MAJOR OIL LOSS. THE PILOT ELECTED TO RETURN TO THE DEPARTURE AIRPORT WITHOUT SHUTTING THE ENGINE DOWN. AN UNEVENTFUL LANDING WAS MADE. GROUND INSP FOUND NO OIL LEFT IN THE ENGINE. THE PROBLEM WAS TRACED BACK TO A LEAK FROM THE OVERSPEED GOVERNOR PAD GASKET. THE GASKET WILL BE RETURNED TO SERVICE INVESTIGATION FOR EXAMINATION AND THE ENGINE WILL LIKELY BE REMOVED AND SENT FOR REPAIRS.

CA110627001

 

PWA   

 

TURBINE BLADES

FRACTURED

5/24/2011

 

PT6A65B

 

 

ENGINE

POST FLIGHT INSPECTION DISCOVERED THERE WAS 1EA 2ND STAGE PT ROTOR BLADE SEPARATED FROM THE MIDDLE SPAN OF BLADE. THE PILOTS REPORTED EVERYTHING WAS NORMAL DURING THE FLIGHT. INVESTIGATION REVEALED BLADE FRACTURED BY FATIGUE. MFG RECOMMENDS THE SDR BE CLOSED ON THE BASIS OF THE FOLLOWING INFORMATION.

CA110614004

 

PWA   

 

GOVERNOR

MALFUNCTIONED

6/8/2011

 

PT6A67D

 

 

PROPELLER

ABORTED TAKEOFF DURING TAKEOFF ROLL, AS THE PILOT ADVANCED THE POWER LEVER, THE ENGINE ACCELERATED AND WITH A TARGET PROPELLER SPEED OF 1700 RPM SET, IT WENT TO 1803 RPM AND THE SPEED COULD NOT BE CONTROLLED. THE T/O WAS ABORTED. TROUBLESHOOTING IS FOCUSING ON A FAULTY PROPELLER GOVERNOR. RECOMMENDS THE SDR BE CLOSED ON THE BASIS OF THE FOLLOWING INFORMATION.

CA110606009

 

PWA   

 

BEARING

MAKING METAL

6/1/2011

 

PW119B

 

 

RGB  

EIR PW100 2011-034 WAS ABLE TO CONFIRM THE OPERATORS REPORT OF METAL CONTAMINATION IN THE RGB OIL SYS. THE SOURCE OF THE METAL CONTAMINATION WAS DETERMINED TO BE THE RT NR 14 BEARING WHICH HAD A CRACKED AND SPALLED INNER RACE. THE CAUSE OF THE FAILURE COULD NOT BE DETERMINED.

CA110614002

 

PWC   

 

FUEL CONTROL

MALFUNCTIONED

6/7/2011

 

PW617FE

 

 

 

POWER ROLL BACK DURING INITIAL CLIMB N1 SPEED DROPPED TO 50 PERCENT AND T/O RESERVE WAS ACTIVATED. AFTER A FEW SECONDS, THE ENGINE RECOVERED AND OPERATED NORMALLY. AFTER LANDING AT HOME BASE, THE ENGINE WAS VISUALLY INSPECTED AND NO DAMAGE WAS FOUND. ANALYSIS OF THE DATA RECORDER CONFIRMED THE POWER ROLL BACK. TROUBLESHOOTING IS FOCUSING ON A FAULTY FADEC. RECOMMENDS THE SDR BE CLOSED ON THE BASIS OF THE FOLLOWING INFORMATION.

CA110204010

AEROSP

TMECA

 

BELT

CRACKED

2/4/2011

AS355*

ARRIEL1D1

 

POLYV597K4

HYD PUMP

DURING ROUTINE MX, THE HYD DRIVE WAS DISASSEMBLED AND UPON INSP THE HYD PUMP DRIVE BELT WAS FOUND TO HAVE A SMALL CRACK ACROSS THE V-GROOVES. THE BELT WAS REPLACED.

EE4Y1010520

AIRBUS

 

 

SPAR

CORRODED

9/8/2011

A319132

 

 

54530252200

ZONE 400

LT WING T/E PYLON AFT FAIRING BONDING JUMPER ATTACHMENT POINT WITH CORROSION. THE PART IS GOING TO BE REPLACED.

EE4Y20110527

AIRBUS

 

AIRBUS

SKIN

DEBONDED

9/14/2011

A319132

 

 

D5547100400000

RUDDER

VERTICAL STABILIZER, RUDDER LT SIDE PANEL WITH WATER INGRESS INSIDE THE HONEYCOMB CORE AROUND HOISTING POINT NR 3. NOTE: THE RUDDER LT SIDE PANELS REQUIRES A MAJOR REPAIR IAW GUIDELINES.

EE4Y20110534

AIRBUS

 

 

ANCHOR FITTING

CORRODED

9/14/2011

A319132

 

 

D57259162001

ZONE 600

RT WING, INNER SPAR BETWEEN RIB 2 AND RIB 3, MLG RETRACTION JACK ANCHORAGE FITTING'S BORE AND LOWER FACE WITH CORROSION.

EE4Y20110535

AIRBUS

 

 

ANCHOR FITTING

CORRODED

9/14/2011

A319132

 

 

D57259162000

ZONE 500

LT WING, INNER SPAR BETWEEN RIB 2 AND RIB 3, MLG RETRACTION JACK ANCHORAGE FITTING'S BORE AND LOWER FACE WITH CORROSION.

EE4Y20110521

AIRBUS

 

 

FLOOR SUPPORT

CORRODED

9/13/2011

A319132

 

 

D5347217220500

ZONE 200

PAX CABIN, UPPER REAR FUSELAGE FLOOR SUPPORT WITH CORROSION AT C67 -Y1292.0.

EE4Y20110523

AIRBUS

 

AIRBUS

HINGE FITTING

CRACKED

9/13/2011

A319132

 

 

D55982000200

LT ELEVATOR

LT ELEVATOR HINGE FITTING NR 1 ANTI-ROTATION TAB, CRACKED. REPAIRED IAW MSG NR 70522342/003.

EE4Y20110524

AIRBUS

 

 

FLOOR SUPPORT

CORRODED

9/13/2011

A319132

 

 

D5347219620000

FUSELAGE

PAX CABIN AFT ENTRY FLOOR SUPPORT AREA FROM FR68 TO FR70, FLOORBEAM WITH CORROSION. REPAIRED FLOOR SUPPORT FROM FR68 TO FR70 AFT ENTRY AREA IAW SRM 51-72-11, PAR 4 AND 6.

EE4Y20110522

AIRBUS

 

 

FLOOR SUPPORT

CORRODED

9/14/2011

A319132

 

 

D5347213320700

ZONE 200

PAX CABIN FLOOR SUPPORT WITH CORROSION AT FRAME 66 -Y1292.0. NOTE: THE FLOOR SUPPORT WILL BE REPLACED IAW SRM.

EE4Y20110528

AIRBUS

IAE   

 

SKIN

CORRODED

9/14/2011

A319132

V2524A5

V2524A5

 

NR 1 PYLON

NR 1 PYLON SECTION INBD AND OTBD AFT FIXED FAIRING PANELS WITH CORROSION. NOTE: THE INBD AND OTBD FIXED FAIRING PANELS WILL BE REPLACED IAW SRM 51-72-11, PARAGRAPH 4 AND 6.

EE4Y20110529

AIRBUS

IAE   

 

SKIN

CORRODED

9/14/2011

A319132

V2524A5

V2524A5

 

NR 2 PYLON

NR 2 PYLON SECTION INBD AND OTBD AFT FIXED FAIRING PANELS WITH CORROSION. NOTE: THE INBD AND OTBD AFT FIXED FAIRING PANELS WILL BE REPLACED IAW SRM 51-72-11, PARAGRAPH 4 AND 6.

EE4Y20110530

AIRBUS

IAE   

BFGOODRICH

PLATE

WORN

9/14/2011

A319132

V2524A5

 

 

THRUST REVERSER

NR 1 THRUST REVERSER INBD C DUCT, PAD DOWN WITH WEAR. NOTE: PAD DOWN PLATE WILL BE REPAIRED IAW SRM 54-30-00, REPAIR 038.

EE4Y20110525

AIRBUS

IAE   

AIRBUS

SKIN

CORRODED

9/14/2011

A319132

V2524A5

 

D54530052203

NR 2 PYLON

NR 2 PYLON AFT FIXED FAIRING, OTBD AND INBD LATERAL SKIN PANEL WITH CORROSION. NOTE: THE FAIRING SKIN PANELS REQUIRE A MAJOR REPAIR IAW SRM GUIDELINES.

EE4Y20110531

AIRBUS

IAE   

BFGOODRICH

PAD   

WORN

9/14/2011

A319132

V2524A5

 

 

THRUST REVERSER

NR 1 THRUST REVERSER OTBD C-DUCT, PAD DOWN WITH WEAR. NOTE: PAD DOWN WILL BE REPAIRED IAW SRM 54-30-00, REPAIR 038.

EE4Y20110526

AIRBUS

IAE   

AIRBUS

SKIN

CORRODED

9/14/2011

A319132

V2524A5

 

D54530052202

NR 1 PYLON

ENGINE NR 1, PYLON AFT FIXED FAIRING, OTBD AND INBD LATERAL SKIN PANEL WITH CORROSION. NOTE: THE FAIRING SKIN PANELS REQUIRE A MAJOR REPAIR IAW SRM GUIDELINES.

EE4Y20110532

AIRBUS

IAE   

BFGOODRICH

PAD   

WORN

9/14/2011

A319132

V2524A5

 

 

THRUST REVERSER

NR 2 ENGINE INBD THRUST REVERSER C DUCT INNER SIDE AFT SECTION PAD DOWN PLATE WITH WEAR. NOTE: THE PAD DOWN WILL BE REPAIRED IAW SRM 54-30-00, REPAIR 038.

EE4Y20110533

AIRBUS

IAE   

BFGOODRICH

PAD   

WORN

9/14/2011

A319132

V2524A5

 

 

THRUST REVERSER

NR 2 ENGINE OTBD THRUST REVERSER C DUCT INNER SIDE AFT SECTION, PAD DOWN PLATE WITH WEAR. NOTE: PAD DOWN WILL BE REPAIRED IAW SRM 54-30-00 REPAIR 038.

EE4Y20110504

AIRBUS

IAE   

 

FLOOR SUPPORT

CORRODED

9/7/2011

A319132

V2524A5

 

D5347219320000

ZONE 200

UPPER FUSELAGE PAX CABIN AFT ENTRANCE AREA FROM FR67 TO FR68 Y-765 FLOOR SUPPORT CORRODED. REPLACED FLOOR SUPPORT IAW SRM 51-72-11 PAR 4 AND 6.

EE4Y20110505

AIRBUS

IAE   

 

FLOOR SUPPORT

CORRODED

9/7/2011

A319132

V2524A5

 

D5347218820400

ZONE 200

UPPER FUSELAGE PAX CABIN AFT ENTRANCE AREA FROM FR68 TO FR69 AT Y1162.5 FLOOR SUPPORT WITH CORROSION. REPLACED FLOOR SUPPORT IAW SRM 51-72-11, PAR 4 AND 6.

EE4Y20110506

AIRBUS

IAE   

 

FLOOR SUPPORT

CORRODED

9/7/2011

A319132

V2524A5

 

D5347218920400

ZONE 200

UPPER FUSELAGE PAX CABIN AFT ENTRANCE AREA FROM FR68 TO FR69 Y-1162.5 LATERAL FLOOR SUPPORT CORRODED. REPLACED FLOOR SUPPORT IAW SRM 51-72-11 PAR 4 AND 6.

EE4Y20110507

AIRBUS

IAE   

 

FLOOR SUPPORT

CORRODED

9/7/2011

A319132

V2524A5

 

D5347217220500

ZONE 200

UPPER FUSELAGE PAX CABIN AFT ENTRANCE AREA FROM FR67 TO FR68 BETWEEN Y-1292 Y-1162.5 LATERAL SUPPORT CORRODED. REPLACED FLOOR SUPPORT IAW SRM 51-72-11, PAR 4 AND 6.

EE4Y20110508

AIRBUS

IAE   

 

FLOOR SUPPORT

CORRODED

9/7/2011

A319132

V2524A5

 

D5347217220400

ZONE 200

UPPER FUSELAGE PAX CABIN AFT ENTRANCE AREA FROM FR67 TO FR68 BETWEEN Y1292 AND Y1162.5 LATERAL FLOOR SUPPORT CORRODED. REPLACED FLOOR SUPPORT IAW SRM 51-72-11 PAR 4 AND 6.

EE4Y20110509

AIRBUS

IAE   

 

SKIN

CORRODED

9/7/2011

A319132

V2524A5

V2524A5

 

NR 1 PYLON

NR1 ENGINE, PYLON AFT LOWER SECTION INBD AND OTBD SKIN WITH CORROSION. REPLACED NR 1 ENGINE PYLON AFT LOWER T/E INBD AND OTBD SKIN PANELS IAW SRM 51-72-11, PAR 5 AND 6.

EE4Y20110510

AIRBUS

IAE   

 

SKIN

CORRODED

9/7/2011

A319132

V2524A5

V2524A5

 

NR 2 PYLON

NR 2 ENGINE, PYLON AFT LOWER SECTION INBD AND OTBD SKIN WITH CORROSION. REPLACED NR 2 ENGINE PYLON AFT LOWER T/E INBD AND OTBD SKIN PANELS IAW SRM 51-71-11 PAR 5 AND 6.

2011FA0000547

AIRPTS

 

 

SPRING

BROKEN

6/14/2011

A9B   

 

 

 

BREAKER POINTS

THE CAM FOLLOWER SPRING THAT IS A PART OF THE BREAKER POINT ASSY IN THE RT MAGNETO BROKE COMPLETELY OFF AT APPROX ITS MID POINT, RESULTING IN TOTAL FAILURE OF THAT MAGNETO.

2011FA0000548

AIRPTS

 

SLICK

CAM FOLLOWER

BROKEN

7/20/2011

A9B   

 

 

M3081

BREAKER POINTS

THE CAM FOLLOWER SPRING THAT IS A PART OF THE BREAKER POINT ASSY IN THE LT MAGNETO BROKE COMPLETELY OFF AT APPROX ITS MID POINT, RESULTING IN TOTAL FAILURE OF THAT MAGNETO. NOTE: THIS FAILURE OCCURRED APPROX 18 OPERATIONAL HOURS FOLLOWING AN IDENTICAL SUCH FAILURE IN THE RT MAGNETO (REPORTED 6/14/2011). THESE FAILURES OCCURRED ON MAGNETOS WITHIN THE SPECIFIC SN BLOCKS IDENTIFIED IN MSB SB2-08A AND SB3-08A AS POSSIBLY HAVING OTHER DEFECTIVE INTERNAL PARTS (CARBON BRUSH AND CAM. STRONGLY SUSPECT THAT THE SAME SUPPLIER MFG THE OBVIOUSLY DEFECTIVE BREAKER POINTS). STRONGLY SUGGEST THIS TO BE A SERIOUS ISSUE AND POSSIBLY WORTHY OF AIRWORTHINESS DIRECTIVE ACTION (CONSIDER THE 18 HOUR TIME PERIOD BETWEEN FAILURES- COULD HAVE EASILY BEEN 18 MINUTES, WHICH WOULD HAVE RESULTED IN TOTAL ENGINE FAILURE).

2011FA0000567

AIRTRC

PWA   

 

ENGINE

POWER LOSS

8/4/2011

AT301

R1340*

 

ZP101988

 

TOTAL LOSS OF POWER ON TAKEOFF. 500 HOURS SINCE O/H.

CA110601009

AIRTRC

 

 

TUBE

CRACKED

5/30/2011

AT802A

 

 

1102910

FUSELAGE

CRACK FOUND UPPER DIAGONAL TUBE IN AFT FUSELAGE. ACFT IN MOUNTED ON FLOATS.

CA110615004

AIRTRC

 

 

ROLL PIN

MIGRATED

6/9/2011

AT802A

 

 

 

TRIM WHEEL

RUDDER TRIM WHEEL SPINNING FREELY. DURING INVESTIGATION, FOUND ROLL PIN MIGRATED OUT OF TRIM WHEEL (ACTS AS A DOWL PIN) RE-INSTALLED ROLL PIN.

CA110615008

AIRTRC

PWA   

 

PACKING

SPLIT  

6/12/2011

AT802A

PT6A65AG

 

MS28775314

MLG ACTUATOR

ON WALK AROUND, HYD FLUID WAS NOTICED ON RAMP AND ON LT MLG WHEELS. AC POWER WAS TURNED ON AND HYD PUMPS CYCLED AND IT WAS DETERMINED THAT HYD FLUID WAS LEAKING FROM FWD END OF MLG ACTUATOR SHAFT. LT MLG ACTUATOR DISSASSEMBLED AND FOUND PACKING ITEM 38 WAS SPLIT, ALL SEALS REPLACED AND GEAR FUNCTION LEAK CHECKED OK

CA110607011

AIRTRC

PWA   

 

TUBE

CRACKED

6/6/2011

AT802A

PT6A67A

 

1102910

FUSELAGE

CRACK FOUND UPPER DIAGONAL TUBE IN AFT FUSELAGE WHILE DOING SL266 ON THIS TUBE. NOTE: THIS ACFT IN MOUNTED ON FLOATS.

CA110613008

AIRTRC

PWA   

 

MOTOR

INTERMITTENT

6/8/2011

AT802A

PT6A67A

 

D186126

FLAP SYSTEM

(CAN) FLAPS WOULD NOT RETRACT. DEAD SPOT IN FLAP MOTOR CAUSES INTERMITTENT OPERATION. THIS IS A RECURRING DEFECT IN THESE MOTORS. EXPERIENCED THE SAME SNAG LAST YEAR (2010).

2011FA0000572

AMD   

GARRTT

 

THROTTLE CABLE

BINDING

8/28/2011

FALCON900EX

TFE73160

 

4808655

ZONE 100

AT TOP OF DESCENT, NR 2 THROTTLE STUCK AT FULL FWD POSITION , AUTOTHROTTLES DISCONNECTED, MANAGED TO GET THROTTLE BACK TO IDLE HOWEVER IT WAS STUCK THERE AND WOULD NOT ADVANCE. APPEARED TO FREE UP AT AROUND 14000 FT . FLEW 2 ENG APPROCH. NR 2 TELEFLEX CABLE BETWEEN FRAME 34 AND ENG REMOVED , MOISTURE FOUND AT FRAME 34 CONNECTION. NITROGEN BLOWN THROUGH CABLE. CABLE RE-INSTALLED AND RIGGING CHECKED .

2011FA0000566

AMTR

AMTR

 

CRANKSHAFT

BROKEN

8/4/2011

SONEX

4AR1200VOLKS

 

 

ENGINE

CRANK BROKEN AT FLANGE. CAST CRANKSHAFT FAILURE.

CA110516008

AYRES

PWA   

 

ENGINE

POWER LOSS

5/6/2011

S2RT65

PT6A34AG

 

 

 

POWER LOSS (SINGLE ENGINE DURING T/O ROLL, THE ENGINE HAD A POWER LOSS. THE PILOT ABORTED T/O, REDUCED POWER TO IDLE AND SHUT THE ENGINE DOWN. THE ACFT WAS TOWED BACK TO ITS PARKING SPACE AND A GROUND RUN COULD NOT REPRODUCE THE PROBLEM. THE FUEL CONTROL WILL BE REPLACED AS PRECAUTIONARY MEASURE BEFORE THE ACFT IS RETURNED TO SERVICE.

CA110531006

BBAVIA

LYC   

 

CONTROL HANDLE

FAILED

5/26/2011

8GCBC

O360C2E

 

31700

TE FLAPS

PILOT WAS GOING FROM 2 ND TO 4 TH NOTCH OF FLAP AND THE HANDLE FAILED. TT ON PART 1502 HRS.

CA110512002

BBAVIA

LYC   

 

CYLINDER HEAD

CRACKED

5/11/2011

8GCBC

O360C2E

 

LW12427

ENGINE

DURING A 100HR INSP, A CRACK WAS DISCOVERED COMING FROM THE LOWER SPARK PLUG HOLE PROCEDING TOWARDS THE EXHAUST VALVE. IT IS COMMON PRACTICE IN THE FACILITY TO BORESCOPE THE CYLINDERS AT EACH 100 HR INSP TO LOOK FOR SUCH CRACKS AS PREVENTITIVE MX TO REDUCE THE NR OF IN FLIGHT FAILURES.

CA110610008

BEECH

PWA   

 

PRECOOLER

CRACKED

6/5/2011

1900D

PT6A67D

 

1143800025

RT ENGINE AIR

THE PILOT REPORTED THE ENGINE HAD MARGINAL PERFORMANCE DURING HIGH AMBIENT TEMP CONDITIONS WITH ANTI-ICE ON THE ENGINE WAS TEMPERATURE LIMITED. ALL ENGINE AIR SYS WERE INSPECTED AND MX DISCOVERED THE RT ENGINE PRECOOLER HAD CRACKED ON THE INLET SIDE WELD JOINT, AS WELL AS THERE WAS HEAT DAMAGE TO THE ENGINE OIL COOLER WHERE THE HOT AIR LEAK HAD MELTED SOME FINS. BOTH ASSEMBLIES WERE REPLACED AND THE ACFT WAS RETURNED TO SERVICE.

2011FA0000689

BEECH

 

BEECH

ATTACH FITTING

CRACKED

10/19/2011

200BEECH

 

 

1011100731

ZONE 500

WHILE ACCOMPLISHING A WING BOLT INSPECTION, THE LEFT HAND, LOWER WING SPAR ATTACH SHEAR FITTING WAS FOUND CRACKED. THE CRACK WAS APPROXIMATELY 0.75" LONG AND LOCATED IN THE FORWARD FLANGE AREA.

CA110530012

BEECH

PWA   

 

BEARING

SEIZED

5/20/2011

200BEECH

PT6A41

 

21400100

NOSE AXLE

UPON INSPECTION OF THE NOSE WHEEL ASSY, IT WAS NOTICED THAT THE RETAINING NUT PN AN7502-24 WAS BACKED OFF AND THE COTTER PIN HAD BEEN SHEARED. THE PIN & NUT WAS REMOVED AND THE WASHER PN MS21258C24 HAD TURNED AND SHEARED THE LOCK TAB OFF AND WAS STUCK TO THE SPACER. THE WHEEL BEARINGS WERE DESTROYED AND SEIZED ONTO THE AXLE. THE WHEEL ASSY HAD TO BE REMOVED BY BEATING IT WITH A HAMMER BY 3 MX. THE WHEEL ASSY WAS REPLACED WITH A SERVICABLE UNIT AND THE ACFT WAS RETURNED TO SERVICE.

2011FA0000583

BEECH

CONT

 

BULB

BROKEN

9/9/2011

A45   

IO550*

 

 

OIL TEMP

OIL TEMP BULB BROKEN IN HALF. ELECTRICAL HALF FELL OUT WITH CONNECTOR, LEAVING HOUSING IN OIL COOLER AND LEAKING.

CA110531007

BEECH

PWA   

 

SEAL

LEAKING

5/12/2011

B200

PT6A42

 

3022375

FCU DRIVE  

ENGINE LOST 3-4 QUARTS DURING PREVIOUS FLIGHT. DURING INVESTIGATION OIL WAS FOUND TO BE COMING FROM THE HIGH PRESSURE FUEL PUMP DRAIN BETWEEN THE ENGINE AND FCU. FCU AND FUEL PUMP WERE REMOVED AND THE SEAL AT THE ENGINE DRIVE WAS FOUND TO HAVE MIGRATED COMPLETELY OUT OF ITS CARRIER AND LYING ON THE SHAFT. SEAL AND CARRIER WERE REPLACED AS WELL AS THE FCU AS A PRECAUTIONARY MEASURE AND THE ACFT RETURNED TO SERVICE.

CA110613015

BEECH

PWA   

 

OIL FILTER

BYPASSING

6/13/2011

C90A

PT6A21

 

307097601

LT ENGINE

OPS 3 AND 4 INSPECTION UNDER WAY FOUND LT ENGINE OIL MAIN FILTER BYPASS CONE SEPARATED AT THE END. REPLACED WITH NEW.

VJ3R20110901001

BEECH

CONT

 

CIRCUIT BREAKER

FAILED

9/1/2011

F33A

IO520BB

 

35380132103

BEACON LIGHT

PILOT REPORTED BEACON LIGHT INOP. ON TROUBLESHOOTING, TECH FOUND CIRCUIT BREAKER/ SWITCH TO BE AT FAULT. AD 2008-13-17 HAD BEEN COMPLETED 2466 FLIGHT HOURS PRIOR. NO PROBABLE CAUSE OR RECOMMENDATIONS AT THIS TIME.

VJ3R20110901002

BEECH

CONT

 

CIRCUIT BREAKER

FAILED

9/1/2011

F33A

IO520BB

 

35380132103

LANDING LIGHT

PILOT REPORTED LANDING LIGHT INOPERATIVE. ON TROUBLESHOOTING, TECHN FOUND CIRCUIT BREAKER/ SWITCH TO BE AT FAULT. AD 2008-13-17 HAD BEEN COMPLETED 2079 FLIGHT HOURS PRIOR AND ESTIMATED CYCLES 8316. NOTICED NEW CIRCUIT BREAKER MFG. NO PROBABLE CAUSE OR RECOMMENDATIONS AT THIS TIME.

VJ3R20110901003

BEECH

CONT

 

CIRCUIT BREAKER

FAILED

9/1/2011

F33A

IO520BB

 

35380132103

LANING LIGHT

PILOT REPORTED LANDING LIGHT INOPERATIVE. ON TROUBLESHOOTING TECH FOUND CIRCUIT BREAKER/ SWITCH TO BE AT FAULT. AD 2008-13-17 HAD BEEN COMPLETED 1552 FLIGHT HOURS PRIOR AND ESTIMATED CYCLES 6208. NOTICED NEW CIRCUIT BREAKER MFG. NO PROBABLE CAUSE OR RECOMMENDATIONS AT THIS TIME.

VJ3R20110901004

BEECH

CONT

 

CIRCUIT BREAKER

FAILED

9/1/2011

F33A

IO520BB

 

35380132101

NAVAGATION LIGHT

MECHANIC REPORTED NAV LIGHT CIRCUIT BREAKER FELT WEAK. AD 2008-13-17 HAD BEEN COMPLETED 1552 FLIGHT HOURS PRIOR AND ESTIMATED CYCLES 6208. NOTICED NEW CIRCUIT BREAKER MFG. NO PROBABLE CAUSE OR RECOMMENDATIONS AT THIS TIME.

CA110509012

BELL  

ALLSN

 

BLADE

CRACKED

5/6/2011

206B

250C20

 

206016201131

TAIL ROTOR

DURING AN AFTER LAST FLIGHT CHECK, A CRACK WAS FOUND ON THE TAIL ROTOR BLADE RUNNING PARALLEL WITH THE T/E, ADJACENT TO THE CHORDWISE BALANCE WEIGHT.

CA110503008

BELL  

ALLSN

 

BULKHEAD

CRACKED

5/3/2011

206B

250C20

031004159

206030446001F

TAILBOOM

2 CRACKS FOUND ON TAILBOOM BULKHEAD. CRACKS GENERATED FROM THE HOLES FOR T/R GEARBOX STUDS, FOUND DURING TAIL ROTOR GEAR BOX ATTACHMENT CHECK ON 300 HOUR AIRFRAME INSPECTION.

2011FA0000574

BELL  

ALLSN

 

STUD

WORN

9/3/2011

206L1

250C28

 

68870991

OIL CAP

ACFT WAS IN CRUISE FLT, PILOT NOTICED OIL PRESSURE DEMINISHING, PILOT INITIATED LANDING. ONCE ACFT WAS ON THE GROUND PILOT NOTICED OIL PRESSURE AT FLUCTUATING FROM ZERO TO 30 PSI, AND ALSO NOTICED SMOKE COMING FROM ENGINE. ENGINE WAS SHUTDOWN AND MX WAS CALLED OUT. UPON ARRIVAL, TECH NOTICED OIL ON BOTH SIDES OF MID FUSELAGE. UPON FURTHER INSPECTION, WITH ENGINE COWLING REMOVED, NOTICED THAT THE ENGINE OIL FILTER CAP WAS NOT FULLY SEATED. PROCEEDED TO FURTHER INSPECT AND FOUND THAT 1 OF THE STUDS THAT SECURES THE CAP DOWN HAD WORN THREADS.

CA110206002

BELL  

PWA   

 

STIFFENER

CRACKED

1/28/2011

212   

PT6T3B

 

212030099027

TAILBOOM

STIFFENER, IN BASE OF FIN FOUND CRACKED ALONG FLANGE AGAINST SKIN.

CHIR20110902001

BOEING

GE   

GE   

PIN   

WORN

9/2/2011

1072

CT581101

 

82609

PRUIFIER SHAFT

CENTRIFUGAL PURIFIER RECEIVED FOR REPAIR DUE TO REPORTED LOOSE SHAFT. DISCREPANCY CONFIRMED AND FOUND PIN HOLDING SHAFT IN PLACE SEVERELY WORN.

EE4Y1108001

BOEING

 

 

ANGLE

CRACKED

8/29/2011

7372H4

 

 

 

ZONE 100

PAX CABIN BS 597 BETWEEN S-17L AND S-18L WITH ANGLE CRACKED. THE PART CRACKED WAS REPLACED.

EE4Y1108002

BOEING

 

 

STRINGER CLIP

CRACKED

8/29/2011

7372H4

 

 

69353642

ZONE 200

PAX CABIN BS 1006 STRINGERS CLIP CRACKED. THE PARTS WERE REPLACED.

EE4Y1108003

BOEING

 

 

BEAM

CRACKED

8/29/2011

7372H4

 

 

654653723

ZONE 200

UPPER FUSELAGE BS 578, RBL 65 STUB BEAM UPPER CHORD CRACKED. THE PART CRACKED WAS REPLACED.

EE4Y20110919001

BOEING

 

 

SKIN

DENTED

9/19/2011

7372H4

 

 

654577453

ZONE 100

LOWER FUSELAGE STA 774, BETWEEN STRINGER 24L AND STRINGER 25L SKIN WITH DENT. A PERMANENT REPAIR IS INSTALLED FOLLOWING MFG REPAIR GUIDELINES UNDER WO Z10226, ITEM 1-101.

EE4Y20110919002

BOEING

 

 

SKIN

DENTED

9/19/2011

7372H4

 

 

654577453

ZONE 100

LOWER FUSELAGE BS 816, STRINGER 20 SKIN WITH DENT. A PERMANENT REPAIR IS INSTALLED FOLLOWING MFG REPAIR GUIDELINES UNDER WO Z10226, ITEM 1-44.

EE4Y20110919003

BOEING

 

 

SKIN

DENTED

9/19/2011

7372H4

 

 

654577453

ZONE 100

LOWER FUSELAGE AT STA 819 BETWEEN STRINGER 22L AND STRINGER 23L SKIN WITH DENT. A PERMANENT REPAIR IS INSTALLED IAW REPAIR GUIDELINES UNDER WO Z10226 ITEM 1-43.

5PHR20110831001

BOEING

PWA   

 

PLUG

MISINSTALLED

7/18/2011

767   

PW4060

 

38311466

FUEL/OIL COOLER

EVALUATION CONDUCTED BY MFG. REPAIR ACTIONS AND HISTORY PRIOR TO INVESTIGATION, TO BE PROVIDED BY OPERATOR OR ITS SUPPLIER. HISTORY OF OVERTEMP/ENGINE SHUTDOWN. UNIT WAS REPAIR AT OPERATOR, VENDOR GA TELESIS. THE VALVE FAILED TO OPERATE DURING RECEIVING TESTS. THE FAILURE WAS ISOLATED TO THE LAP ASSY SECTION SINCE THE SOLENOID MET ALL TEST REQUIREMENTS. DISASSEMBLY AND INSP OF THE LAP ASSY SHOWED THE UNIT WAS INCORRECTLY ASSEMBLED. THE PLUG IN THE LAP ASSEMBLY WAS INSTALLED INCORRECTLY (BACKWARDS). THE RESULT WAS NO SPRING LOAD TO HOLD THE SLIDE ASSY IN THE CORRECT OPERATIONAL POSITION. THE SLIDE ASSY WAS FREE TO SHUTTLE TO THE BYPASS OR NORMAL OPERATION MODE NEGATING THE INTENT OF THE SOLENOID ASSY TO CORRECTLY DIRECT THE INLET FLOW TO THE OUTLET OR BYPASS PORTS .

2011FA0000569

BOEING

 

 

BRAKE

FRACTURED

8/10/2011

767424ER

 

 

 

NR 7  

AFTER ACFT DEPARTURE, THE AIRPORT AUTHORITY FOUND SEVERAL BRAKE DEBRIS ON THE INNER TAXIWAY NEAR THE POSITION 17. THE DEBRIS HAVE BEEN GIVEN TO OUR LINE MX PERSONNEL, AND HAVE MX STORE. FOLLOWING THIS QUICK INVESTIGATION, IT APPEARS THAT THE BRAKE DISK AND PISTON DEBRIS FOUND ON THE TAXIWAY ARE VERY SIMILAR TO THE DISK INSPECTED ON THE SPARE BRAKE. FURTHER TO THIS RESULT, MX HAS BEEN INFORMED AND PICTURES OF THE DEBRIS SENT TO THEM FOR DEEPER INVESTIGATION. THE ACFT HAD BEEN INSPECTED BEFORE FLIGHT AND ETOPS PRE-DEPARTURE CHECK PERFORMED. DURING THE INSP/CK NO REMARKS OR DISCREPANCIES HAD BEEN REPORTED. AFTER ACFT ARRIVAL, MX CONFIRMED THAT THE AFT INNER BRAKE (NR 7) WAS DAMAGED AND THAT THE DEBRIS FOUND WERE COMING FROM THAT BRAKE.

2011FA0000571

CESSNA

CONT

CESSNA

BELLCRANK

LOOSE

9/4/2011

150C

O200A

 

 

RUDDER

HAVING REMOVED THE RUDDER FOR AN UNRELATED ISSUE, IT WAS FOUND THAT THE BELLCRANK WAS LOOSE. FURTHER EXAMINATION REVEALED THAT ALL THE RIVETS SUPPORTING THE BELLCRANK AND ADJACENT STRUCTURES WERE LOOSE IN THEIR RESPECTIVE MOUNTING HOLES. THE BOTTOM OF THE RUDDER SPAR, PN 0431001-16 WAS CRACKED IN 2 PLACES. LIKEWISE, THE BOTTOM RIB, PN 0431001-17 WAS ALSO CRACKED. EVIDENCE SUGGESTS THAT THE RUDDER INSTALLED IS NOT ORIGINAL.

CA110621010

CESSNA

LYC   

 

CAMSHAFT

WORN

6/21/2011

152   

O235L2C

 

SL75706

ENGINE

INTAKE LOBE NR 1 IS ALMOST COMPLETELY WORN DOWN.

CA110609005

CESSNA

LYC   

 

TUBE

SPLIT  

6/9/2011

172N

O320H2AD

 

500X5

TIRE  

ACFT WAS PARKED ON RAMP AFTER FLIGHT AND A COUPLE HOURS LATER A PASSING PILOT NOTICED THE NOSE TIRE COMPLETELY FLAT. MX REMOVED THE TIRE AND DISCOVERED THAT THE TUBE HAD A 1" LONG SPLIT IN IT. THIS HAS BEEN A COMMON OCCURRENCE ON THIS SIZE OF TUBE OVER THE LAST WHILE. TUBE WAS REPLACED.

CA110613010

CESSNA

LYC   

 

BULKHEAD

CRACKED

6/10/2011

172P

O320D2J

 

05503214

PROP SPINNER

PROPELLER SPINNER BULKHEAD HAS SEVERAL CRACKS AROUND BOLT HOLES.

CA110601011

CESSNA

LYC   

 

COVER

CRACKED

6/1/2011

172R

IO360L2A

 

 

FLOW DIVIDER

ON SCHEDULED INSPECTION, THE FLOW DIVIDER COVER PLATE WITH THE 4 COUNTERSUNK SCREWS HOLDING IT DOWN WAS FOUND TO HAVE MULTIPLE CRACKS FROM 3 OUT OF THE 4 BOLT HOLES ON BOTH SIDES.

CA110608006

CESSNA

LYC   

 

TERMINAL

BROKEN

6/6/2011

172R

IO360L2A

 

 

ALTERNATOR

ALTERNATOR FAILURE IN FLIGHT, UNSCHEDULED LANDING, ON T/S SYS FOUND THE ALTERNATOR B & WIRE TERMINAL END BROKEN OFF AT THE B+ CONNECTION AT ALTERNATOR. TIME ON THE ACFT IS 5662, UNKNOWN IF TERMINAL END HAS BEEN CHANGED IN THE PAST.

CA110613012

CESSNA

LYC   

 

GROUND WIRE

CORRODED

6/10/2011

172R

IO360L2A

 

 

ALTERNATOR

THE GROUND TERMINAL OF THE ALTERNATOR WAS CORRODED/DIRTY MAKING BAD CONTACT. THE OIL TEMPERATURE GAUGE WAS "BACK READING" OFF THIS WHICH CAUSED THE GAUGE TO READ HIGH. CESSNA TECH REP WAS ADVISED OF THE PROBLEM AND RECOMMENDED THIS TO CHECK AS A SOLUTION WHICH FIXED THE INDICATION PROBLEM. THE INITIAL PROBLEM WAS THE OIL TEMP GAUGE WENT TO THE RED LINE DURING FLIGHT.

2011FA0000579

CESSNA

 

 

SWITCH

FAILED

9/8/2011

172S

 

 

CM35895

NAVAGATION LIGHT

ALL NAV LIGHTS INOPERATIVE ON PREFLIGHT , TROUBLESHOOT SYS FOUND SWITCH CM3589-5 FAILED, THIS IS THE 5TH SWITCH OF THIS PN CHANGED ON THIS MODLE OF ACFT. HOURS VARY FROM 500 TO 3714.

CA110610005

CESSNA

LYC   

 

CONTROL CABLE

WORN

6/7/2011

172S

IO360L2A

 

052264710

AILERONS

STAINLESS STEEL AILERON CABLES FOUND WORN AT FAIRLEAD IN RT WING ABOVE ROLL SERVO, AT FAIRLEAD IN LT WING, AND AT THE 3 SMALL PULLEYS IN THE CABIN CEILING. TT 1645, RT AILERON CABLES SHOWED THIS SAME PROBLEM AT ABOUT 600 TT, CABLES WERE REPLACED AND SDR SUBMITTED AT THAT TIME. REF US FAA SAIB CE-11-36. MFG IS ADDRESSING THE PROBLEM.

CA110620008

CESSNA

LYC   

 

DISTRIBUTOR GEAR

LOOSE

6/17/2011

172S

IO360L2A

 

K3008

MAGNETO

AT ROUTINE 500 HR MAGNETO INSPECTION, THE DISTRIBUTOR FINGER OF THE DISTRIBUTOR GEAR WAS FOUND TO BE LOOSE - DISTRIBUTOR GEAR REPLACED.

2011FA0000675

CESSNA

CONT

 

CASTING

CRACKED

10/13/2011

182G

O470R

 

07416031

MLG ATTACH

CASTING CRACK FOUND BY VISUAL INSPECTION DURING COURSE OF ANNUAL INSPECTION. THE CRACK IS LOCATED ON THE FORWARD END OF THE SUPPORT CASTING AND RUNS FROM 1/4 INCH FROM MOUNT HOLES ON THE OUTBOARD SIDE TO WITHIN 1/4 INCH OF THE MOUNT HOLES ON THE INBOARD SIDE OF THE CASTING.

2011FA0000561

CESSNA

CONT

CESSNA

BULKHEAD

CRACKED

7/28/2011

182M

O470R

 

07126161

TAIL CONE

WHILE PERFORMING A VISUAL INSP OF THE AFT FUSELAGE BULKHEAD IAW AD 72-07-09; DISCOVERED CRACKS IN THE AFT BULKHEAD BETWEEN THE RUDDER CABLE CUTOUT AND THE BULKHEAD FLANGE (BOTH SIDES). FOLLOWING THE INSTRUCTIONS IN THE AD, PERFORMED A TORQUE CHECK OF THE BOLTS IN THE FORWARD VERTICAL STABILIZER SPAR AND DISCOVERED THAT THEY WERE LOOSE. THE BULKHEAD HAS BEEN REPLACED, ALL AD REQUIREMENTS HAVE BEEN MET, AND THE ACFT RETURNED TO SERVICE. THIS MALFUNCTION/DIFFICULTY REPORT IS BEING SUBMITTED TO COMPLY WITH THE REPORTING REQUIREMENTS OF THE AD.

CA110611001

CESSNA

PWA   

 

B-NUT

BROKEN

6/8/2011

208   

PT6A114

 

 

HYD SYSTEM

THE ACFT LANDED AND WAS PROCEEDING DOWN THE RUNWAY NORMALLY UNTIL THE PILOT APPLIED THE BRAKES IN PREPARATION FOR LT TURN ONTO TAXIWAY, THE ACFT STARTED TURNING TO THE LT AND PROCEEDED OFF THE RUNWAY AND DOWN AN EMBANKMENT JUST BEFORE THE TAXIWAY TURNOFF. THE PILOT NOTICED THAT THE RT BRAKE FELT SPONGY AS COMPARED TO THE LT. AFTER INSPECTING THE BRAKE ASSEMBLIES, IT WAS NOTICED THAT THE BRAKE LINE FOR THE RT SIDE BRAKE (NR 4 UNIT) WAS NOT ATTACHED TO THE BRAKE ASSY AS THE B-NUT WAS MISSING FROM THE HOSE. A SEARCH WAS CARRIED OUT FOR THE B-NUT BUT IT WAS NOT FOUND.

2011FA0000582

CESSNA

CONT

 

GEAR

SHEARED

8/12/2011

421B

GTSIO520H

 

AEC646655

ALTERNATOR

PILOT REPORTED IN FLIGHT LOSS OF ALTERNATOR. ACFT LANDED W/O INCIDENT. INVESTIGATION REVEALED ALTERNATOR DRIVE CLUTCH GEAR. MISSING DAMPNER MATERIAL AND ALTERNATOR SHAFT BROKEN AT END OF ARMATURE. CUT OIL FILTER OPEN, FOUND TO BE FULL OF STEEL FILINGS. ALTERNATOR AND DRIVE CLUTCH INSTALLED 12-2009. LAST OIL CHANGE ON THIS ENGINE 13 HRS PRIOR. NO METAL DETECTED IN FILTER MEDIA AT THAT TIME. NO OPERATIONAL PROBLEMS NOTED PRIOR TO FAILURE.

2011FA0000568

CESSNA

 

 

BOLT

MISINSTALLED

8/25/2011

525   

 

 

 

MLG  

DURING A ROUTINE OPS CHECK OF THE LANDING GEAR EMERGENCY EXTENSION SYS, THE TEST FAILED TO ACTIVATE THE EMERGENCY BLOW DOWN SYS. UPON FURTHER INVESTIGATION, IT WAS FOUND THAT THE ATTACHING BOLT CONNECTING THE ACTIVATION CABLE TO THE ARM OF THE NITROGEN BOTTLE HAD BEEN INSTALLED AT A HORIZONTAL POSITION. THIS CAUSED THE BOLT HEAD TO COME IN CONTACT WITH THE SUPPORT BRACKET THAT MOUNTS THE BOTTLE. THIS CAUSED THE BOLT HEAD TO JAM IN THIS POSITION BEFORE ACTIVATION OF THE BOTTLE, THUS NOT EXTENDING THE LANDING GEAR FULLY. DURING REINSTALLATION THE BOLT WAS ROTATED 90 DEGREES TO END UP BEING MOUNTED VERTICALLY AND THE PROBLEM WAS ELIMINATED.

2011FA0000546

CESSNA

WILINT

 

BEARING

NOISY

8/10/2011

525   

FJ44

 

060001501

NR 2 GYRO

NR 2 COMPASS SYS PRECESSING. ON INITIAL POWER ON NR 2 GYRO (KG-102A) BEARINGS SOUND NORMAL. 15 MINUTES LATER BEARINGS SOUND LIKE GRAVEL.

Z5FA2011F00191

CESSNA

WILINT

 

FUEL CONTROL

FAILED

9/1/2011

525B

FJ443A

 

77697

ENGINE

RIGHT ENGINE FUEL DELIVERY UNIT FAILED IN FLIGHT, R & R AND THE ACFT RETURNED TO SERVICE.

2011FA0000575

CESSNA

WILINT

CESSNA

VALVE

CRACKED

9/7/2011

525B

FJ443A

 

420001263

ZONE 100

PRESSURE CYLINDER REGULATOR VALVE FOR THE EMERGENCY EXTENSION OF THE LANDING GEAR AND EMERGENCY BRAKES FOR THE AIRCRAFT HAD A CRACK IN IT. FAILURE OF THE VALVE DUE TO CRACKING WOULD RESULT IN LOSS OF PRESSURE TO EXTEND THE LANDING GEAR IN THE EMERGENCY EXTENSION MODE OR FAILURE OF THE WHEEL BRAKES TO OPERATE IN THE EMERGENCY MODE.

2011FA0000551

CESSNA

PWA   

 

BULKHEAD

CRACKED

8/29/2011

550   

JT15D4

 

551202035

ZONE 200

DURING POST FLIGHT VISUAL CHECK, THE MECHANIC NOTICED EVIDENCE OF A CRACK IN THE TAILCONE LT BULKHEAD FRAME AFT OF ENGINE CARRY-THROUGH BEAM AT FS 367.48. THE CRACK WAS VERY SMALL IN THE RADIUS. R & R BY DIRECT REPLACEMENT WITH NEW PART FROM MFG.

CWQR20110831016

CESSNA

 

 

CONTROL CABLE

FRAYED

8/31/2011

560XL

 

 

666000134

ELEVATOR TRIM

DURING A SCHEDULED INSPECTION FOUND ELEVATOR TRIM CABLE FRAYED AT LEAST HALF WAY THROUGH. THIS CABLE IS A PART OF A LARGER CABLE ASSY, PN 6660003-1. THIS CABLE HAS BEEN A SUBJET OF SL, BUT THESE CABLES HAVE IN THE PAST AND CONTINUE TO FRAY PREMATURELY. A SERVICE CONDITION REPORT HAS BEEN FILED WITH MFG UNDER NR 585949.

CA110613016

CESSNA

CONT

 

CONTROL CABLE

BROKEN

6/8/2011

A185F

IO550D

 

 

RUDDER

DURING INSPECTION OF CONTROL CABLES, FOUND RT RUDDER RETURN CABLE BROKEN AT SWAGED BALL TERMINAL.

CA110531008

CESSNA

CONT

 

WIRE

BURNED

5/31/2011

U206F

IO520F

 

 

ALTERNATOR

ACFT LOST RADIO COMMUNICATIONS IN FLIGHT. RETURNED TO DEPARTURE AIRPORT. MX FOUND A BURNED WIRE ON THE ALTERNATOR AND REPAIRED. ALTERNATOR REPLACED.

FCPA201108260011

CIRRUS

 

 

TRANSMITTER

LEAKING

8/26/2011

SR22

 

 

151415001

FUEL FLOW

DURING ENGINE 100 HR INSP, FOUND FUEL FLOW TRANSMITTER LEAKING FUEL AT TOP CAP.

JR2R2011090100358

CNDAIR

 

 

INTERCOSTAL

CRACKED

9/1/2011

CL6002D24

 

 

SH69037060

FUSELAGE

INTERCOSTAL CRACKED AT STATION 855 AND STR 25R.

3S8R201109020003

DHAV

 

 

DOUBLER

CRACKED

9/2/2011

DHC8102

 

 

85410893106

NACELLE

419CT HAS CRACKED DOUBLER AT POINT OF FINGERNAIL. REPLACED DOUBLER IAW SRM 51-42-05.

3S8R201109020004

DHAV

 

 

SUPPORT ANGLE

CRACKED

9/2/2011

DHC8102

 

 

85350282103

 

LEFT UPPER T-DUCT SUPPORT ANGLE CRACKED. REPLACED ANGLE IAW DHC8102, SRM 51-42-05 AND AC43,13-1B, PAGE 4-22, PAR 4-57.

3S8R201109020005

DHAV

 

 

SUPPORT ANGLE

CRACKED

9/2/2011

DHC8102

 

 

85350282104

 

RT UPPER T-DUCT SUPPORT ANGLE CRACKED. REPLACED ANGLE IAW DHC8102 SRM 51-42-05 AND AC43, 13-1B, PAGE 4-22, PAR 4-57.

3S8R201109020006

DHAV

 

 

FRAME

CRACKED

9/2/2011

DHC8102

 

 

85310380

FUSELAGE

NLG WHEEL WELL FRAME CRACKED AT Z112.000 AND X110.000, RT OF CTR LINE (GEAR RELEASE CABLE HOLE). CUT OUT DAMAGE AND INSTALLED REPAIR PARTS IAW DHC8102 RD 8-53-7878 AND 11973.

3S8R201109020002

DHAV

PWA   

 

RIB   

CRACKED

9/2/2011

DHC8102

PW120A

 

85411377101A

NACELLE

429CT FITTING CRACKED ON FINGERNAIL. REPLACED FITTING IAW SRM 54-78-11 AND 51-40-00.

3S8R201109020007

DHAV

 

 

BRACKET

CRACKED

9/2/2011

DHC8103

 

 

83210014009

FAIRING

LEFT MLG DRAG STRUT AFT FAIRING ATTACHMENT BRACKET CRACKED IN 2 PLACES. R & R ATTACHMENT BRACKET IAW SRM 51-40-11.

3S8R201109020009

DHAV

 

 

HEAT SHIELD

GOUGED

9/2/2011

DHC8103

 

 

85410726

ENGINE EXHAUST

NR 2 ENGINE FINGERNAIL UPPER SURFACE PATCH (HEAT SHIELD) DAMAGED. R & R FINGERNAIL PATCH IAW RD 8-54-177.

3S8R201109020008

DHAV

 

 

ANGLE

CRACKED

9/2/2011

DHC8103

 

 

8541073410110

NACELLE

RT OTBD ENGINE AFT NACELLE LOWER STIFFENER ANGLES CRACKED. COMPLIED WITH PERMANENT REPAIR OF BOTH ANGLES, IAW 8-54-310.

CA110516011

DIAMON

ROTAX

GOODYEAR

TUBE

FAILED

5/13/2011

DA20A1

ROTAX912F3

 

 

TIRE  

AFTER A NORMAL LANDING, THE PILOT FOUND THE ACFT PULLING TOWARD THE RT AND ENDED UP STOPPING IN GRASS BESIDE THE RUNWAY. FOUND THAT THE RT MAIN TIRE WAS COMPLETELY FLAT. MX REPLACED THE TIRE AND TUBE AND FOUND THE TUBE HAD FAILED AND HAD A .2500" LONG SPLIT IN THE TUBE. THIS TUBE WAS IN SERVICE FOR LESS THAN A YEAR AND IT HAS BEEN A COMMON PROBLEM WITH THIS SIZE OF TUBE IN THE LAST COUPLE OF YEARS. THE TUBE IS MADE A LOT SMALLER THAN PREVIOULY MADE IN THAT THE TUBE MUST STRETCH A LOT BEFORE IT EXPANDS TO THE SIZE OF THE TIRE. PREVIOUSLY THE TUBE WAS MADE TO BE THE SAME SIZE AS THE TIRE. HAVE TRIED DIFFERENT BRANDS AND HAVE COMPLAINED TO SUPPLIERS BUT ALL THE TUBES, EVEN OF DIFFERENT BRANDS, SEEM TO BE MADE THE SAME.

CA110607013

DIAMON

ROTAX

 

TUBE

SPLIT  

6/6/2011

DA20A1

ROTAX912F3

 

5005  

RT TIRE

AFTER LANDING PILOT DISCOVERED RT TIRE WAS FLAT. TIRE WAS REMOVED AND DISSASSEMBLED AND LARGE SPLIT FOUND IN TUBE (THERE WAS NO EVIDENCE OF PUNCTURE). THIS HAS BEEN HAPPENNING TOO OFTEN LATELY WITH THIS SIZE OF TIRE TUBE. IN MY OPINION THE TUBE IS MADE TOO SMALL FOR THE SIZE OF TIRE AND IT HAS TO EXPAND TOO MUCH TO MEET THE SIZE OF THE TIRE. ALL MFG SEEM TO MAKE THEM THE SAME.

CA110601006

DIAMON

ROTAX

 

LIFTER

WORN

5/20/2011

DA20A1

ROTAX912F3

 

881831

ENGINE

WHILE TROUBLESHOOTING HIGH OIL CONSUMPTION THE OWNER DISCOVERED UNUSUAL WEAR ON NR 2 EXHAUST LIFTER. THE LIFTER CONTACT SURFACE WAS FOUND TO BE WORN WITH PITTING MARKS. 2 OF THE OTHER LIFTERS APPEAR NORMAL IN WEAR PATTERN WITH NO PITTING BUT THE REST OF THE LIFTERS ALSO SHOW SLIGHT WEAR/PITTING MARKS THAT ARE CONSISTENT WITH THE WEAR ON THE NR2 EXHAUST LIFTER. THE CAMSHAFT APPEARS NORMAL. ENGINE WILL BE REPAIRED WITH NEW LIFTERS AND A NEW CAM AS A PRECAUTIONARY MEASURE. IT IS NOT KNOWN IF THE HIGH OIL CONSUMPTION WAS RELATED TO THE LIFTER WEAR.

CA110512001

DIAMON

CONT

 

LEVER

WORN

5/11/2011

DA20C1

IO240B

 

63255512

THROTTLE

DURING CRUISE FLIGHT PILOT REPORTEDLY TRIED TO REDUCE POWER TO IDLE, WAS UNABLE, RETURNED TO HOMEBASE AND LANDED UNEVENTFULLY USING MIXTURE IDLE CUT-OFF. UPON INSP OF THROTTLE LINKAGE IT WAS DISCOVERED SPLINES ON THROTTLE LEVER AND SHAFT WORN. IT IS SPECULATED THAT THE LEVER WAS INSTALLED ON SHAFT WITH SPLINES MISALIGNED, AFTER AN UNDETERMINED AMOUNT OF TIME SPLINES MAY HAVE REALIGNED THEMSELVES BUT WITH SOME `PLAY` IN ACTUATION, CAUSING ADDITIONAL WEAR TO CONTINUE UNTIL SUCH TIME LEVER WOULD ROTATE ON SHAFT WITHOUT ROTATING LEVER. ORIGINALLY MFG HAD "NO" SPLINES ON LEVER, BUT LEVER WAS MADE FROM A SOFTER MATERIAL , IE BRONZE, ALLOWING IT TO "SET" IN PLACE ON SS, THROTTLE SHAFT.

CA110531005

DIAMON

CONT

 

TUBE

WORN

5/27/2011

DA20C1

IO240B

 

2227271100

RUDDER PEDAL

PRIOR TO START-UP THE PILOT NOTICED THAT HE WASN`T ABLE TO ADJUST THE RUDDER PEDALS, AFTER A VISUAL INSPECTION THE AME NOTICED THAT THE LT PILOT SIDE RUDDER PEDALS "S" TUBE HAD THE RUDDER CABLE PROTRUDING FROM ONE OF THE BEND. BOTH PILOT SIDE RUDDER PEDALS WERE REPLACED AND FURTHER INSP REVEALED THAT THE RT SIDE HAD SOME SIGNIFICANT WEAR. ALL OF FLEET HAS BEEN VISUALLY INSPECTED AND NO FURTHER PROBLEMS FOUND. THE MFG HAS NO TIME LIMITS ON THE PEDALS, WE WILL IMPLEMENT A MANDATORY "S" TUBE REPLACEMENT AT THE RUDDER CABLES REPLACEMENT. (3000 HRS)

2011FA0000563

DIAMON

CONT

 

PUMP

LEAKING

7/22/2011

DA20C1

IO240B

 

5367001

FUEL BOOST

ENGINE SHUTDOWN IN FLIGHT. UPON INSPECTION, FOUND A FINE DARK PARTICULATE CONTAMINATING FUEL SYS. AIRFRAME BOOST PUMP APPEARED TO BE SOURCE OF CONTAMINATION. THE AIRFRAME BOOST PUMP WAS LEAKING FUEL FROM ISOLATION CHAMBER BETWEEN PUMP AND MOTOR SECTIONS OF BOOST PUMP AND FROM THE SEAM WHERE THE PUMP SECTION ATTACHES TO THE ISOLATION CHAMBER. PUMP O/H 11/10/09.

2011FA0000545

DIAMON

LYC   

 

INSERT

DEFORMED

8/8/2011

DA40

IO360M1A

 

PFS8016

MUFFLER

FOUND MUFFLER INSERT INNER BAFFLE DEFORMED DURING AN ANNUAL INSPECTION.

2011FA0000552

EMB   

 

 

STATIC PORT  

MISREPAIRED

8/24/2011

EMB500

 

 

100442107

ZONE 100

PRIOR TO INSTALLATION OF AN OVERHAULED DUAL STATIC PORT IT WAS NOTED THAT 1 OF THE AN FITTINGS THAT CONNECTS TO 1 OF THE STATIC LINES WAS DAMAGED ON THE SEATING SURFACE. A BENCH LEAK CHECK WAS PERFORMED AND THE LEAK RATE WAS BEYOND LIMITS. MFG SUPPLIED INSTALLATION DATA TO INSTALL A NEW FITTING, A SECOND LEAK CHECK WAS PERFORMED AND NO LEAKS WERE DETECTED. ON 4 OTHER OCCASIONS STARTING ON 2/26/2011 WE HAVE HAD SIMILAR ISSUES WITH DUAL STATIC PORTS, PN 100442-105, SN 807475 AND 804159, 100442-106, SN 807584, AND 100442-107, SN 835466, ALL OVERHAULED OR REPAIRED BY O/H FACILITY THAT HAVE LEAKED PRIOR TO INSTALLATION. IN MOST CASES THE CONNECTING AN FITTINGS WERE VISIBLY DAMAGED. ALL HAD 8130S ATTACHED.

CA110617005

GRUMAN

WRIGHT

 

CARBURETOR

MALFUNCTIONED

6/15/2011

FIRECAT

982C9HE2

 

PD12K18

ENGINE

NR 1 ENGINE RUNNING EXTREMELY RICH DURING PREFLIGHT RUNUP, CARBURETOR REPLACED.

2011FA0000544

GULSTM

CONT

 

BOLT

LOOSE

8/22/2011

112A

IO360*

 

AN46A7A

HORIZONTAL STAB

WHILE COMPLYING WITH AD 11-07-13 LT AND RT ELEVATOR SPAR, IT WAS NOTED THAT THE HORIZONTAL STAB WAS LOOSE AT BOTH THE FRONT AND REAR MOUNTING POINTS. MOVEMENT WAS MOST NOTED AT THE FWD PORTION OF THE STAB WITH A ROCKING MOVEMENT SIDE TO SIDE. UPON INVESTIGATION IT WAS FOUND THAT ALL 10 BOLTS WERE TURNED A COMPLETE REVOLUTION TO TORQUE. REMOVED BOLTS AND EXAMINED HOLES FOR ELONGATION AND DAMAGE. NONE NOTED. TORQUED BOLTS TO FACTORY RECOMMENDED TORQUE VALVES. RECOMMENDED THAT THIS TORQUE VALVE BE CHECKED IMMEDIATELY, AND AT YEARLY INSPECTION. LOG BOOK RESEARCH SHOW THAT BY RECORD NO WORK HAD BEEN DONE TO EITHER THE HORIZONATAL OR TO THE VERTICAL FIN.

GR4D20110907001

GULSTM

 

GULSTM

LINK

CORRODED

9/7/2011

GIV   

 

 

1159M413235

ZONE 400

LEFT SUSPENSION LINK CORRODED.

CA110620011

HUGHES

ALLSN

 

SHAFT

SHEARED

6/18/2011

369D

250C20B

 

 

GOVERNOR

PILOT WAS IN A HOVER, NOTICED THAT THE NR/N2 RPM HAD INCREASED BY 3 PERCENT, BEEPED RPM DOWN AND CONTINUED HOVERING OPERATION AND THE RPM INCREASED AGAIN. ELECTED TO LAND AND UPON LANDING THE ENGINE STARTED TO OVERSPEED SO THE PILOT ROLLED THROTTLE OFF IMMEDIATELY. UPON REMOVAL OF THE GOVERNOR IT WAS DISCOVERED THAT THE SHAFT HAD SHEARED JUST BEHIND THE SPRING, JUST FORWARD OF THE NUT ON THE SHAFT.

CA110517002

MOONEY

LYC   

 

CAMSHAFT

MAKING METAL

4/25/2011

M20F

IO360A1A

 

LW1884015B26064

ENGINE

INSPECTION OF OIL FILTER DURING ROUTINE MX REVEALED SMALL FERROUS METAL PARTICLES THAT WARRANTED FURTHER INVESTIGATION RESULTING IN THE REMOVAL OF NR 1 CYLINDER. IT WAS DISCOVERED THAT THE NR1 INTAKE TAPPET WAS SEVERELY GALLED. THE ENGINE WAS REMOVED FOR REPAIR AND SENT TO ENGINE FACILITY. UPON DISASSEMBLY ALL CAMSHAFT LOBES WERE FOUND TO BE WORN AND DAMAGED TO VARYING DEGREES. ALL BUT 2 OF THE TAPPET BODIES WERE SEVERELY GALLED. THE REMAINING 2 SHOWED SIGNS OF DISTRESS AND SURFACE IRREGULARITY (1 & 3 EXHAUST). AS A RESULT OF THE METAL CONTAMINATION THE FOLLOWING COMPONENTS WERE RENDERED UNSERVICEABLE: OIL PUMP HSG, ALL BRGS (MAINS AND RODS), 8 PISTON PIN PLUGS AND ALL 4 PISTONS (SKIRT DAMAGE). ENG WAS O/H 132.0 HRS. AGO AND CAMSHAFT AND LIFTERS WERE INSTALLED NEW.

2011FA0000577

NAMER

 

 

STRUT

FAILED

8/6/2011

T28C

 

 

G75482

NLG  

DURING ROLLOUT AND AT APPROX 500' AFTER NOSE WHEEL TOUCHED DOWN AT LANDING, THE LOWER SECTION OF THE NOSE STRUT BROKE OFF. STRUT BROKE AT POINT WHERE THROUGH-BOLT IS INSTALLED. THIS BOLT HOLDS THE LOWER SECTION OF THE OLEO STRUT (PISTON) TO THE NOSE GEAR FORK.

2011FA0000581

PIAGIO

 

 

HYDRAULIC SYSTEM

MALFUNCTIONED

9/8/2011

P180

 

 

 

 

DURING GEAR RETRACTION LOSS OF HYD POWER DUE TO POPPED CIRCUIT BREAKER. RE-ENGAGED C/B AND PERFORMED 20 MORMAL EXTENSIONS & RETRACTIONS OF THE LANDING GEAR, EACH TIME THE LANDING GEAR AND HYD SYS OPERATED NORMAL IAW 32-30-00, COULD NOT DUPLICATE CREW DISCREPANCY.

CA110525006

PIAGIO

PWA   

 

HOSE

COLLAPSED

5/24/2011

P180

PT6A66

 

80337485001

BLEED AIR SYS

FOUND DURING A SCHEDULED INSPECTION, RIGHT ENGINE BLEED AIR SUPPLY HOSE INTERIOR WALL COLLAPSED WHILE THE EXTERIOR WALL WAS STILL SERVICEABLE.

XHCR20110831001

PILATS

 

 

BOOT

FAILED

8/31/2011

PC1245

 

 

 

ZONE 600

AFTER INSTALLATION OF A FULL SET OF PNEUMATIC DEICE BOOTS ON THE ACFT, PROCEEDED TO PERFORM THE OPS TEST OF THE PNEUMATICE DEICE BOOT SYSTEM. AT WHICH TIME, IN THE APPROPRIATE TIME IN THE SEQUENCE OF INFLATION, THE RT WING INBD BOOT HAD INFLATED PROPERLY, BUT BEFORE THE SEQUENCE WAS ENDED AND IT WAS DEFLATING, THE BOTTOM, INBD, AFT SECTION OF THE BOOT RELIEVED THE AIR PRESSURE AT A HIGH RATE. HALTED THE OPS CYCLE AT THAT TIME. UPON INSPECTION OF THE BOOT, FOUND THE "WING SIDE OF THE BOOT HAD ADHERED TO THE WING PROPERLY AND WAS NOT AT FAULT, BUT THE "STITCHING" THAT FORMS THE CHANNELS IN THE BOOT, HAD LET GO AND CONSEQUENTLY SPLIT THE SEAM ON THE AFT SIDE OF THE BOOT, SEPARATING THE LAYERS OF THE BOOT, CAUSING IT TO DUMP AIR OVERBOARD.

2011FA0000557

PILATS

 

 

BOOT

FAILED

8/31/2011

PC1245

 

 

 

ZONE 600

AFTER INSTALLATION OF A FULL SET OF PNEUMATIC DEICE BOOTS ON THE ACFT, PROCEEDED TO PERFORM THE OPS TEST OF THE PNEUMATICE DEICE BOOT SYSTEM. AT WHICH TIME, IN THE APPROPRIATE TIME IN THE SEQUENCE OF INFLATION, THE RT WING INBD BOOT HAD INFLATED PROPERLY, BUT BEFORE THE SEQUENCE WAS ENDED AND IT WAS DEFLATING, THE BOTTOM, INBD, AFT SECTION OF THE BOOT RELIEVED THE AIR PRESSURE AT A HIGH RATE. HALTED THE OPERATIONAL CYCLE AT THAT TIME. UPON INSPECTION OF THE BOOT, IT WAS FOUND THE THE "WING SIDE OF THE BOOT HAD ADHERED TO THE WING PROPERLY AND WAS NOT AT FAULT, BUT THE "STITCHING" THAT FORMS THE CHANNELS IN THE BOOT, HAD LET GO AND CONSEQUENTLY SPLIT THE SEAM ON THE AFT SIDE OF THE BOOT, SEPARATING THE LAYERS OF THE BOOT, CAUSING IT TO DUMP AIR OVERBOARD.

5APR20110904001

PILATS

PWA   

BFGOODRICH

DISK

CRACKED

9/4/2011

PC1245

PT6A67B

 

244759D

BRAKE ASSY

THE LT BRAKE ASSEMBLY WAS INSPECTED DURING A LINE CHECK AND FOUND TO HAVE A CRACKED ROTOR. THE LT BRAKE ASSEMBLY WAS R & R USING A SERVICEABLE UNIT OF THE SAME PN-959.56.01.512 IAW AMM 12-A-32-40-03-00A-920B-A.

5APR20110902001A

PILATS

PWA   

 

MOTOR

FAULTY

9/2/2011

PC1245

PT6A67B

 

9599022126

COMPRESSOR

VCCS SYS REPORTED AS INOPERATIVE, FANS BLOWING BUT AIR IS NOT COLD. THE VCCS COMPRESSOR MOTOR WAS FOUND FAULTY AND WAS R & R WITH SERVICEABLE UNIT OF THE SAME PN 959-90-22-126, IAW CMM 21-00-23 AND AMM 12-A-21-50-01-00A-920B-A.

5APR20110829001

PILATS

PWA   

PWC   

BLADES

ERODED

8/29/2011

PC1245

PT6A67B

 

 

TURBINE

DURING A ROUTINE HOT SECTION BOROSCOPE INSP, SEVERAL COMPRESSOR TURBINE BLADES WERE FOUND TO HAVE EROSION THAT EXTENDED INTO THE BLADE TIPS. ENGINE PERFORMANCE RUNS AS WELL AS CURRENT ECTM GRAPHS WERE NORMAL, NO HOT SECTION DETERIORATION WAS OBSERVED. THE POWER SECTION WAS REMOVED, HOT SECTION COMPONENTS INSPECTED AS NECESSARY. THE CT DISK WAS REPAIRED BY INSTALLING NEW CT BLADES 43 (EA). THE REPAIRED CT DISK ASSY WAS REINSTALLED INTO THE POWER SECTION. THE POWER SECTION WAS REINSTALLED AND ALL ASSOCIATED TESTS WERE ACCOMPLISHED WITH NO FURTHER FAULTS FOUND, ALL IAW AMM 12-A-72-10-00-00A-920A-A, 12-A-71-00-00-00A-903A-A AND EMM 72-50-01 ,72-50-02 AND 72-00-00.

5APR577Y86

PILATS

PWA   

 

BLADES

ERODED

8/30/2011

PC1247

PT6A67B

 

 

TURBINE DISK

DURING A ROUTINE HOT SECTION BOROSCOPE INSP, SEVERAL COMPRESSOR TURBINE BLADES WERE FOUND TO HAVE EROSION THAT EXTENDED INTO THE BLADE TIPS. ENGINE PERFORMANCE RUNS AS WELL AS CURRENT ECTM GRAPHS WERE NORMAL, NO HOT SECTION DETERIORATION WAS OBSERVED. THE POWER SECTION WAS REMOVED, HOT SECTION COMPONENTS INSPECTED AS NECESSARY. THE CT DISK WAS REPAIRED BY INSTALLING NEW CT BLADES 43 (EA). THE REPAIRED CT DISK ASSEMBLY WAS REINSTALLED INTO THE POWER SECTION. THE POWER SECTION WAS REINSTALLED AND ALL ASSOCIATED TESTS WERE ACCOMPLISHED WITH NO FURTHER FAULTS FOUND, ALL IAW AMM 12-A-72-10-00-00A-920A-A, 12-A-71-00-00-00A-903A-A AND EMM 72-50-01 ,72-50-02 AND 72-00-00.

CA110513009

PIPER

LYC   

 

HUB   

CRACKED

5/13/2011

PA14

O320*

 

 

PROPELLER

PROPELLER RECEIVED FOR A CORROSION INSP IAW CAR 625. PAINT WAS REMOVED, HUB CAUSTIC SODA ETCHED AND LPI`ED. 5 CRACKS WERE FOUND. LOCAL REWORK WAS ATTEMPTED TO A DEPTH OF 0.032 " AND INDICATIONS REMAIN. AFTER CONSULTATION WITH THE MFG THE PROPELLER IS UNSERVICEABLE AND BEYOND REPAIR.

2011FA0000578

PIPER

LYC   

 

ENGINE

MAKING METAL

5/1/2011

PA18150

O360C4P

 

0360C4P

 

THE ENGINE NEVER DEVELOPED RATED HP. SINCE NEW. THEN FAILED TO MEET STATIC RPM. THE ENGINE ALWAYS GENERATED AN EXCESSIVE AMOUNT OF METAL. OIL SCREEN WAS CHECKED AND STEEL WAS PRESENT. ENGINE RETURNED TO MFG FOR THE SECOND TIME FOR TESTING.

CA110518011

PIPER

LYC   

 

HOSE

BROKEN

5/17/2011

PA31350

LTIO540J2BD

 

19310004D0330PT

FUEL INDICATING

PILOTS REPORTED HIGHER THAN NORMAL FUEL FLOW ON RT ENGINE. FOUND SENSE HOSE, THAT RUNS BETWEEN ENGINE INTAKE MANIFOLD TO DIFFERENTIAL PRESSURE CONTROLLER, BROKEN NEAR THE CONTROLLER HOSE FITTING. HOSE ASSY. REPLACED. NOTE: THIS PARTICULAR HOSE HAS BEEN FOUND BROKEN/CRACKED ON NUMEROUS ENGINE INSTALLATIONS. THIS HOSE IS EXPOSED TO EXCESSIVE HEAT AT THE CONTROLLER AREA AND PREMATURELY BECOMES VERY BRITTLE AND EVENTUALLY BREAKING. THE HOSE MATERIAL AT PRESENT IS REINFORCED RUBBER COMPOUND. SUGGEST A HIGH TEMP STEEEL BRAIDED OR HIGH TEMP FIRE SLEEVE PROTECTED HOSE BE USED IN THIS INSTALLATION.

2011FA0000570

PIPER

 

 

BEARING

TORN

9/2/2011

PA31T

 

 

80859002

RUDDER PEDAL

DURING EVENT 1 INSPECTION RUDDER PEDAL TORQUE TUBE SUPPORT BEARING, PN 80859-002 WAS FOUND TO BE TORN FREE FROM THE FUSELAGE STRUCTURE WHERE IT ATTACHES BELOW THE CENTER INSTRUMENT PANEL.

2011FA0000555

PIPER

 

 

HOSE

LEAKING

4/7/2011

PA31T

 

 

AE7010201K0240

OIL PRESSURE

ACFT HAD DEPARTED AND WAS ENROUTE AT CRUISE ALTITUDE. PILOT NOTICED DROP IN OIL PRESSURE ON LT ENGINE. DIVERTED, UPON ARRIVAL WHEN EXITING ACFT, FOUND ENGINE OIL SPREAD FROM REAR OF LT ENGINE COWLING ACROSS LT LOWER WING AND FLAP AND ONTO REAR FUSELAGE. OIL LEVEL ON LT ENGINE DIPSTICK SHOWED AT BOTTON OF DIPSTICK. REMOVED TOP LT COWLING AND INSPECTED ACCESSORY SECTION OF ENGINE. NO OBVIOUS SIGNS OF LEAK. WASHED ENGINE AND SERVICED WITH 8 QTS. BP2380 AND MOTORED ENGINE TO BUILD UP OIL PRESSURE. PRESSURE CAME UP TO 60 P.S.I. AND RECHECKED ACCESSORY SECTION. FOUND OIL DRIPPING OFF OF LOWER HOSE BETWEEN OIL COOLER AND ACCESSORY SECTION. REMOVED HOSE AND FOUND HOSE SATURATED UNDER FIRESLEEVE. REMOVED FIRESLEEVE AND FOUND IN AREA WHERE RADIUS WAS VERY TIGHT STEEL BRAIDING HAD CRACKED AND CUT INTO RUBBER HOSE. REPLACED HOSE ASSY WITH NEW HOSE ASSY, PN AE7010201K0240. WASHED ACCESSORY SECTION WITH SOLVENT AND PERFORMED LOW POWER ENGINE RUN. NO LEAKS FOUND. TOPPED OFF ENGINE OIL. OWNER PERFORMED LOCAL FLIGHT AND ON RETURN ONLY RESIDUAL OIL WAS FOUND COMING FROM LOWER COWLING. ACCORDING TO OWNER ALL ENGINE HOSES HAD BEEN REPLACED A SHORT TIME BEFORE THIS INCIDENT.

2011FA0000580

PIPER

LYC   

 

POWERPACK

FAILED

8/15/2011

PA32R301T

TIO540*

 

HYC5005

HYD SYSTEM

LANDING GEAR HYD POWER PACK FAILED ON FIRST FLIGHT AFTER INSTALLATION. POWER PACK WAS O/H REF WO 3505.

C41R20110907102

PIPER

 

 

GUARD

TORN

9/6/2011

PA46350P

 

 

105892002

LWR CABIN DOOR

DURING 100 HR INSPECTION, FOUND LOWER DOOR SUPPORT CABLE SHEATHS TORN. REPLACED CABLES. BELIEVE THIS IS CAUSED BY THE SHEATH NOT BEING SECURED TIGHTLY TO THE CABLE THE FULL LENGTH. WHEN PASSENGERS DEPART THE PLANE, THEY GRAB THE CABLE AND THE SHEATH SLIPS, CAUSING THE EXCESS STRESS, CAUSING THE TEARS. THIS SHEATH SHOULD BE GLUED THE FULL LENGTH, OR REPLACED WITH A LOOSELY FITTING LEATHER COVERING ATTACHED WITH VELCRO. THIS WOULD ALSO ALLOW FOR INSPECTION OF THE CABLE.

C41R20110907101

PIPER

 

 

SWITCH

OUT OF ADJUST

9/6/2011

PA46350P

 

 

688345

TE FLAPS

OWNER REPORTED FLAPS INTERMITTENTLY WOULD NOT GO FROM 10 TO 20 DEGREES UNLESS SELECTOR HANDLE WAS MANIPULATED. FOUND FLAP SWITCHES ON SELECTOR CAM TO BE OUT OF ADJUSTMENT. SLIGHT PRESSURE ON SELECTOR HANDLE ROD WOULD ACTUATE FLAPS AS NORMAL. ADJUSTED FLAP SWITCHES IAW MM. OPS CKS OK.

E81R20110830001

RAYTHN

 

 

PIN   

MISSING

8/30/2011

G36   

 

 

116X12

FRONT SEAT ASSY

INVESTIGATED PILOT COMPLAINT OF NOT BEING ABLE TO MOVE COPILOT'S SEAT FORWARD OR AFT. FOUND CENTER TRACK LOCKING PIN NOT LIFTING HIGH ENOUGH TO DISENGAGE FROM TRACK LOCK HOLES. AFTER REMOVING SEAT AND PARTIALLY DISASSEMBLING TRACK LOCKING MECHANISM, FOUND .032" STAINLESS STEEL SAFETY WIRE SUBSTITUTED FOR PN .0625 X .5 LOCKING PIN THAT SECURES PN 36-530026-49 TRACK LOCKING PIN TO OPERATING MECHANISM. SAFETY WIRE HAD ELONGATED LOCKING PIN HOLE IN TRACK LOCK PIN TO EXTENT EXCESSIVE SLOP IN MECHANISM WOULD NOT ALLOW TRACK LOCKING PIN TO OPERATE HIGH ENOUGH TO RELEASE SEAT. REPLACED THE TRACK LOCK PIN AND INSTALLED WITH CORRECT HARDWARE IAW THE G36 IPC. SEAT OPERATIONS NORMAL FOLLOWING REPAIR. MAINTENANCE RECORDS UNAVAILABLE, NOT KNOWN IF SEAT WAS REPAIRED FOLLOWING AIRCRAFT BUILD.

CA110517004

ROBSIN

LYC   

 

YOKE

WORN

5/16/2011

R22BETA

O320B2C

 

A9084

M/R GEARBOX

MAIN ROTOR GEARBOX YOKE FOUND LOOSE ON 100HR INSPECTION. FLEX PLATE WAS REMOVED TO REVEAL NUT AND COTTER PIN INTACT. WASHER UNDER NUT HAD A STEP WORN IN IT. BACK OF NUT WAS FOUND TO HAVE WEAR. YOKE HAS VISIBLE STEPS WORN IN IT. ADVISED RHC. THEY REQUESTED PICTURES FOR DIAGNOSIS. PICTURES OF NUT/WASHER, YOKE AND MRGB INPUT SPLINES PROVIDED. RHC ADVISED TO INSTALL NEW YOKE, WASHER AND NUT. TORQUE NUT TO HIGH SIDE OF TORQUE SPREAD, LOCTITE YOKE ON SPLINE AND CHECK FOR MOVEMENT AND LOOSNESS EVERY OIL CHANGE.

CA110420011

ROBSIN

LYC   

 

CONTROLLER

FLUCTUATES

4/15/2011

R44   

O540F1B5

 

D2781

ENGINE GOVERNOR

ENGINE RPM FLUCTUATING. REPLACED GOVERNOR CONTROLLER.

CA110204003

ROBSIN

LYC   

 

GEAR

CHIPPED

2/2/2011

R44   

O540F1B5

 

 

STARTER BENDIX

(CAN) DURING 50 HOUR INSPECTION STARTER WAS FOUND TO HAVE CHIPPED BENDIX TEETH. STARTER REPLACED.

CA110215012

ROBSIN

LYC   

 

POINTS

CHATTERING

2/13/2011

R44   

O540F1B5

 

 

MAGNETO

POINTS CHATTERING. REPLACED MAGNETO.

CA110214022

ROBSIN

LYC   

 

CARBURETOR

FAILED

2/7/2011

R44   

O540F1B5

 

10603511

ENGINE

CARBURETOR WILL NOT PROVIDE FUEL DURING GROUND RUN. CARBURETOR REPLACED.

CA110519003

ROBSIN

LYC   

 

BRACKET

BROKEN

5/18/2011

R44   

O540F1B5

 

B2001

ALTERNATOR

ON 50 HR INSPECTION, ENGINEER NOTED ALOT OF BLACK SMOKE AROUND THE ALTERNATOR, UPON CLOSER INSPECTION, IT WAS FOUND THAT THE ALTERNATOR BRACKET INBD ARM HAD BROKEN OFF AND THE ALTERNATOR WAS HANGING FROM THE REMAINING ARM. THE BRACKET WAS BROKEN THRU THE BOLT HOLE. ALSO THE BUSHING IN THE ALTERNATOR SUPPORT EAR WAS FOUND TO BE LOOSE. BOTH WERE REPLACED AND THE ACFT RETURNED TO SERVICE.

CA110414005

ROBSIN

LYC   

 

SERVO

LEAKING

3/11/2011

R44RAVENII

IO540AE1A5

 

D2121

HYD SYSTEM

HYD SERVO LEAKING. REPLACED SERVO.

CA110621011

ROBSIN

LYC   

 

DRIVE ASSY

FAILED

6/17/2011

R44RAVENII

IO540AE1A5

 

 

STARTER

STARTER BENDIX DRIVE WAS FOUND TO BE DISENGAGING PREMATURELY. STARTER REPLACED.

CA110415008

ROBSIN

LYC   

 

STARTER

FAILED

4/12/2011

R44RAVENII

IO540AE1A5

 

14924HTH

ENGINE

ACFT WOULD NOT START. STARTER REPLACED.

CA110420010

ROBSIN

LYC   

 

RESERVOIR

LEAKING

4/18/2011

R44RAVENII

IO540AE1A5

 

D2112

HYD SYSTEM

HYD RESERVOIR LEAKING FROM VENT CAP HOLES. RESERVOIR REPLACED.

CA110518009

ROBSIN

LYC   

 

MUFFLER

CRACKED

5/6/2011

R44RAVENII

IO540AE1A5

 

C16932

EXHAUST

FOUND CRACKED UNDER HEATER MUFF SHROUD.

CA110527004

ROBSIN

LYC   

 

SPRAG CLUTCH

CRACKED

5/27/2011

R44RAVENII

IO540AE1A5

 

C1883

MAIN ROTOR

NOISE HEARD ON SHUTDOWN. CLUTCH DISASSEMBLED AND INSPECTED. FOUND THE SPRAG CLUTCH CAGE CRACKED IN SEVERAL PLACES, ALSO INDIVIDUAL SPRAGS CRACKED.

CA110530005

ROBSIN

LYC   

 

RESERVOIR

LEAKING

5/2/2011

R44RAVENII

IO540AE1A5

 

D2112

HYD SYSTEM

HYD RESEVOIR LEAKING. HYD RESEVOIR REPLACED.

CA110613005

ROBSIN

LYC   

 

LINE

CRACKED

5/22/2011

R44RAVENII

IO540AE1A5

 

D7531

ENGINE OIL SYS

PILOT NOTED LOW OIL PRESSURE AND INCREASED OIL TEMP IN FLIGHT. PILOT LANDED AND ACFT WAS INSPECTED. ENGINEER FOUND A LARGE OIL LEAK IN THE AREA OF THE OIL COOLER. INSPECTION FOUND AN OIL LINE SHEARED AT A SWAGE LOK FITTING THAT WAS INSTALLED AS PART OF STC SH06-43 CONFIGURATION 2. FURTHER INVESTIGATION DETERMINED THAT SWAGE LOCK FITTING REQUIRES A MINIMUM LINE THICKNESS OF 0.035". LINES HAVE A WALL THICKNESS OF 0.018" - 0.020". COMPANY REMOVED STC SH06-43 MODIFICATION FROM ALL 16 COMPANY ACFT UNTIL SUCH TIME AS A SUITABLE AMENDMENT CAN BE MADE TO THIS APPROVAL.

CA110504006

SCWZER

 

 

SPAR

MISREPAIRED

4/25/2011

SGS233A

 

 

 

WING  

DURING INSPECTINO, PAINT WAS REMOVED FROM WING AND A LARGE AMOUNT OF FILLER WAS DISCOVERED NEAR THE WING TIP. UPON REMOVAL OF THE FILLER AN UNDOCUMENTED PATCH WAS DISCOVERED. UPON FURTHER INVESTIGATION IT WAS DISCOVERED THAT THE TIP RIB PN 33408-4 AND THE NEXT INBD RIB PN 33411G-4 HAD UNDOCUMENTED DOUBLERS INSTALLED ON THEM. THIS LEAD TO FURTHER INVESTIGATION INTO THE AREA WHICH REVEALED THAT THE MAIN SPAR WEB PN 33402-15 HAD SOME RIPPLING IN IT FROM STA 292.0 OUT TO THE TIP WITH AN UNDOCUMENTED DOUBLER INSTALLED FROM STATION 293.5 TO 299.0. IT WAS ALSO DISCOVERED THAT THE UPPER SPAR CAP ANGLE PN 33402-3 HAD BEEN SPLICED AT STA 280.5 AND THE LOWER SPAR CAP ANGLE PN 33402-3 HAD BEEN SPLICED AT STA 282.0. BOTH OF THESE SPLICES WERE COMPLETED WITH JUST A SMALL PIECE OF STEEL ANGLE BEING ATTACHED TO THE INSIDE OF THE ANGLE, AND WERE NOT DOCUMENTED. UPON TALKING TO THE TYPE CERTIFICATE HOLDER ALL OF THE FOUND UNDOCUMENTED REPAIRS HAVE NOT BEEN COMPLETED PROPERLY AND REQUIRE REPLACEMENT.

CA110504005

SCWZER

 

 

RIB   

MISREPAIRED

4/25/2011

SGS233A

 

 

3340611

 

(CAN) AN UNDOCUMENTED REPAIR WAS FOUND ON THE LEFT HAND WING AT STATION 214.0. UPON REMOVAL OF THE PATCH THE RIB WAS FOUND TO BE BENT OVER. BOTH THE WING SKIN REPAIR AND THE RIB WERE NOT COMPLETED AS PER ANY APPROVED OR ACCEPTED DATA, AND WERE NOT RECORDED IN ANY OF THE AIRCRAFTS LOGS. THIS WORK IS BELIEVED TO HAVE BEEN COMPLETED AS THE ACFT WAS PURCHASED, THERE PREVIOUS REGISTRATION IS N1174S.

3S8R2011041600016

SNIAS

TMECA

 

BEAM

DAMAGED

4/16/2011

SA330J

TURMO4C

 

 

BS 3855-5295

RT LONGITUDINAL BEAM LOWER SKIN AND BEAM DAMAGED. REPAIR TO BE CARRIED OUT IAW MX 20-03-05-420. DAMAGE IS BETWEEN FS 3855 AND 5295.

3S8R2011041600017

SNIAS

TMECA

 

BUSHING

CORRODED

4/16/2011

SA330J

TURMO4C

 

 

LT MLG

LEFT MLG STRUT, EXTERNAL FITTING BUSHING CORRODED AND WORN BEYOND DIMENSIONAL LIMITS. PART WAS REPLACED WITH NEW IAW MFG RE-WORK SHEET 330 21 505 00 BY FACTORY TECHS. ADDITIONALLY, CORROSION WAS REMOVED OUTSIDE THE BALL BUSHING SEAT IAW SAME RE-WORK SHEET.

3S8R2011041600018

SNIAS

TMECA

 

BUSHING

CORRODED

4/16/2011

SA330J

TURMO4C

 

 

CTR FUSELAGE

RIGHT MLG STRUT EXTERNAL FITTING BUSHING CORRODED BEYOND LIMITS. PART WAS REPLACED WITH NEW IAW MFG RE-WORK SHEET 330 21 505 00 BY FACTORY TECHS. ASSEMBLY, CORROSION WAS REMOVED OUTSIDE THE BALL BUSHING SEAT IAW SAME RE-WORK SHEET.