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

327

bald eagle watching over three eggs

OCTOBER

2005

 


CONTENTS

AIRPLANES

BOEING...................................................................................................................................... 1

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

CIRRUS....................................................................................................................................... 5

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

RAYTHEON................................................................................................................................ 9

HELICOPTERS

AUGUSTA................................................................................................................................. 11

ACCESSORIES

B. F. GOODRICH...................................................................................................................... 12

AIR NOTES

ELECTRONIC VERSION OF FAA FORM 8010-4, MALFUNCTION OR
DEFECT REPORT..................................................................................................................... 14

PAPER COPY OF FAA FORM 8010-4, MALFUNCTION OR DEFECT REPORT............... 14

INTERNET SERVICE DIFFICULTY REPORTING (iSDR) WEB SITE................................... 14

IF YOU WANT TO CONTACT US......................................................................................... 15

AVIATION SERVICE DIFFICULTY REPORTS...................................................................... 15

 


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

AVIATION MAINTENANCE ALERTS

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

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

 

AIRPLANES

BOEING

Boeing; 737-7EL; Loose Anticollision Light Lens; ATA 3340

A mechanic describes a potential defect in this aircraft’s anticollision light (P/N 30-0909-20) lens mount located on the tail cone. “While cleaning the lens, it appeared to be loose.... A very gentle pull released the lens from its housing. The lens is thick glass that could be a runway hazard if it fell from the aircraft and broke. The probable cause is Skydrol (hydraulic fluid) which leaked from the rudder PCU (power control unit) and compromised the adhesive features of the sealant attaching the lens to the housing assembly. I recommend inspection of aircraft that have had rudder PCU Skydrol leakage problems. Some type of mechanical attachment of the lens to the housing should be considered.”

Part Total Time:  893.6 hours.

 

CESSNA

Cessna; 172S; Stall Warning Horn Failure; ATA 3418

“A new student pilot was flying a flight school aircraft with a CFI (certified flight instructor),” says this submitting mechanic. “During the student’s first stall practice the warning horn failed to operate through full stall, and the CFI halted the maneuver. Troubleshooting by maintenance personnel confirmed the warning horn assembly (P/N 0713348-1) was defective. The (failed) unit was replaced with a new (assembly), and a maintenance operational check and test flight were completed. This part had 311.7 hours TSN (time since new) and was a replacement for the original, factory installed part...(which failed after 651.0 hours).

“A second 172 aircraft (of three) had the identical problem...at 491.5 hours. In this case the part was replaced twice because the first new part failed during (its) test flight. Aircraft number three has 417.6 hours TSN and has been recently checked: it is okay at this time. (The) probable cause (for these failures) has not been determined.


(I) suggest at least a one time check of all new aircraft be conducted and reported to determine the scope of the problem and to raise awareness of a possible unknown safety problem.”

Part Total Time:  311.7 hours.

 

Cessna; A185F; Worn Tail Wheel Steering Pawl; ATA 3250

The submitter describes an apparent failure of the steering lock pawl (P/N 0742147-6) in the tail wheel of this airplane. “Upon landing...(tail wheel castor swung) ...the aircraft to the right and off the runway. The aircraft sustained damaged to its left wing. Investigation disclosed the tail wheel steering pawl was worn to a point that it would not sufficiently lock the locking collar. (This) reporter’s concern is wear of this pin is not easily apparent -- except through a write-up by a pilot experienced with this problem. Visual inspection of the tail wheel assembly would not disclose this problem.”

Part Total Time:  unknown.

 

Cessna; 206H; Crew Flood Lights -- Confusing Data; ATA 3310

A customer complains the overhead floodlights for the crew seats fail to attain full and/or similar brilliance as those found over passenger seating. The investigating technician said, “The initial troubleshooting seemed to indicate the system was responding correctly but, indeed, the lights only attained about half brilliance as compared to the same type of light assemblies placed for use by the rear seat passengers. (I) contacted a Cessna technical representative and discussed the problem with him. (He) forwarded this (question) to the engineering department, and was told this (reduced illumination) is the way the system was intended to operate. A review of the maintenance manual and the AFM (aircraft flight manual) did not address this (issue). It seems to this reporter this is an operating function that should be addressed by a revision in both the maintenance manual and the AFM as soon as possible to eliminate this type of confusion.”

Part Total Time:  (n/a).

 

Cessna; 404; “Blended” Elevator Cable; ATA 2730

An L/H elevator cable (P/N 5815103-5CR) was found to be blended at the fairlead approximately 6 inches from the aft end of the cable. The technician believes “...the probable cause is from the new style stainless steel Cessna cable. They last only a fraction of the time (as compared to) the old style cables.” (Almost the same description and part number can be found for a Cessna 441:  see last August’s Alerts. September’s Alerts has a similar concern for nose gear steering cables on a Cessna 402.)

Part Total Time: unknown.

 

Cessna; 421B; Improper Installation of Lower Rudder Hinge; ATA 5540

“This aircraft was here (repair station) for a complete exterior repaint,” writes the submitting technician. “After removing the rudder we complied with Cessna service bulletin SB MEB 00-4. It’s just a visual inspection, but it does require removing the rudder.   We found the rudder hinge assembly (P/N 5731026-1) was installed upside down. Being in the aircraft refurbishment business...(and working) many of the effected model airplanes, we have


found about 75 percent of these lower rudder hinge assemblies installed upside down, and many with the bearings falling out and wearing on the rudder hinge brackets. I recommend a one time AD to inspect all effected aircraft....”

Part Total Time:  unknown.

 

Cessna; 750; Loose Seat Locking Screws; ATA 2510

A repair station technician writes, “The screw depicted in Cessna 750-0202 Interior Manual 25-10-06 (page 9, reference number 18) was found loose on both the pilot’s and co-pilot’s seats on two separate occasions, six months apart. These screws were retightened on both occasions. I feel this problem is significant due to the fact the possible failure mode could be loss of seat locking capability and the crew seat being free to move fore and aft. It has been recommended to Cessna Aircraft (using their Service Condition Report) some locking feature should be used for this screw, such as a lock washer or Loctite compound.”


Part Total Time:  1,389.9 hours.

 

 


CIRRUS

Cirrus; SR22; Chafed Hole in Fuel Supply Line; ATA 2820

(This very short defect report was submitted by a mechanic on August 19. It’s subject warrants close scrutiny by owners and operators of this aircraft.)

“The main fuel supply line (P/N 11443-004) from the fuel selector valve to the firewall had a hole chafed in it. The wire bundle to the circuit breaker panel was chafing this line.”

Part Total Time:  750.0 hours.

 

Cirrus; SR22; Inadvertent Door Opening; ATA 5210

The submitter states, “Both doors will ‘pop’ open in flight, causing a safety distraction to the pilot and wind noise that keeps the pilot from hearing ATC (air traffic control) instructions. This still happens, (despite) several trips to a Cirrus authorized repair center and the factory--for repairs. Cirrus’s response is the doors are within specifications and should not come open. (I) have heard from other owners they too have the same problems with the new door design.” (Part numbers for the left and right entry doors were not provided. Those “other owners” have not submitted defect reports, as this entry is the only Cirrus door discrepancy found in the SDR data base.)

Part Total Time: 250.0 hours.

 

PIPER

Piper; PA-25; Gascolator Access Difficulty; ATA 2821

A submitting FAA inspector writes, “During an accident investigation, (this aircraft’s) fuel gascolator was found with large amounts of water and solid contaminants. It was noticed the part could not be rotated to ensure drainage of contaminants...due to cowl support strut interference. This gascolator could be relocated two inches inboard to ensure clearance of the cowl struts. (I) have inspected four other PA-25 aircraft and found the same condition exists:  the contaminants could not be drained out effectively. As Piper no longer supports this aircraft, an airworthiness directive may be needed to fix this problem.”


Part Total Time: unknown.

 

Piper; PA-28; Blocked Throttle; ATA 7322

A student pilot reports their aircraft’s throttle would not advance beyond idle. The attending mechanic determines the carburetor is binding internally. “(I) dissembled the carburetor and found the air metering pin’s stop-pin worn (P/N 62-F1) -- allowing the air metering pin to extend beyond normal range, jamming between the stop-pin and the actuating arm on the pump lever assembly (P/N 155-560).” (This is a Lycoming O-360 engine fitted with a MA4-510-5193 carburetor.)

Part Total Time: 224.9 hours.

 

Piper; PA-31T; Split Hydraulic Line; ATA 2910

A submitter describes the pilot of this aircraft as receiving no response from his gear-down selection. He was on final for landing. “He attempted emergency manual gear extension and ‘felt’ the gear coming down...then he lost hydraulic pressure. The pilot was unable to secure the gear in a down-and-locked (condition). The aircraft sustained substantial damage during emergency landing. Post accident inspection revealed the hydraulic system’s drain/fill line (P/N 46138-00) had ruptured, causing rapid loss the hydraulic reservoir’s contents. This failure prevented sufficient hydraulic system pressure (for either) normal or emergency extension of the landing gear. The line failed parallel to the grain structure...(its rupture measuring approximately one-half inch in length). It is suspected water contamination in the line froze, causing the rupture. (I) suggest regular purging/draining of line contents during planned maintenance.”


Part Total Time: unknown.

 


Piper; PA-31T; Rudder Torque Tube Bearing Support -- Cracked; ATA 2720

A pilot reports unusual yaw characteristics in flight (specificity not provided). The submitting mechanic describes having previously adjusted the rudder cable tension, and is very surprised to find it loose. Subsequent inspection found the rudder torque tube bearing support flange cracked at the aft bolt on the pilot’s side. The mechanic speculates excess rudder pedal force with the aircraft on the ground (and not moving) may have been the cause of this failure. (No part numbers were provided with this report. Despite the low resolution of the attached black and white photograph, the torn flange segment still attached to the torque tube bearing can be seen.)

Part Total Time:  3,539.0 hours.

 


RAYTHEON

Raytheon Beech; 58; Cracked Forward Spar Web; ATA 5714

The submitter states, “During an Annual inspection, cracks were noted in the forward carry-though spar web (P/N 002-430018-5). They are located at the L/H upper, outboard-most Huck bolt holes (2 ea.) on the forward side of the carry-through assembly. The head end of the upper Huck bolt is inaccessible for viewing without wing removal. The lower Huck bolt is accessible and no movement or cracking was noted.

(In accordance with a Designated Engineering Representative’s directions...) the web skin around the Huck bolts was removed down to the underlying web tie plate. The plate was then eddy current inspected for cracks -- none were detected. Per DER instructions, this area will be inspected by fluorescent dye penetrant method every Annual Inspection, and by eddy current method every 500 hours.

“AD 90-08-14 (airworthiness directive) concerns (itself with) cracking in the carry-through webs, and limits cracking at the Huck bolts to one per side. The Beech repair kit (P/N 58-4008) is to be installed if more than one Huck bolt (installation hole) is cracked. This aircraft has two bolt areas cracked on one side, however, the required repair does not extend into this area -- thus the need for this type of (DER) action.

“It is believed the high aircraft time and damage history were contributing factors to the cracking in this area.” (The following two photographs show the cracked web, and its repair, respectively.)

 

 


 

Part Total Time:  12,474.4 hours

 

Raytheon Beech; 58; Leaking Fuel Strainer Gaskets; ATA 2821

A reporter describes this aircraft’s new fuel strainer gasket (P/N 33-199-C) as being made from less ridged material than the original design. “They tend to compress and slide out from under the strainer wall into the center of the fuel strainer body and begin to leak fuel. The strainer housing (P/N 33-199-105-3) is not machined to hold the softer gasket.”

Part Total Time:  100.0 hours.

 

Raytheon Beech; 300; Fuselage Skin Damage; ATA 5330

A repair station mechanic writes, “...a scheduled inspection found the screws attaching the aft lower edges of the forward wing root fairings... to be of excessive length.” The screw tips had gouged the lower fuselage skins to the depth of 0.020 inch at the approximate fuselage station 166.30. “I have noticed similar damage to other 200/300 series King Air aircraft at the same location. (This damage)...requires DER (designated engineering representative) approved repairs to these pressurized fuselage skins. I suggest any technicians inspecting this area to pay close attention for screw tip damage, and to use only the correct length fairing attach screws.” A recommendation for a service bulletin is suggested: either mechanical modification to the fairing attachments, or


inspection and placards for the same. (Damaged skin part numbers were given as 130-430051-7 and 130-430051-8, left/right respectively. The provided fairing part number is 101-420132-5.)

Part Total Time:  4,974.1 hours.

 

Raytheon Beech; 300; Rudder Torque Tube Cable Quadrant Loose; ATA 2720

A technician describes finding a cable quadrant (P/N 101-530057-3) for the autopilot rudder servo -- loose on the rudder torque shaft assembly (P/N 101-524012-15). This defect’s repair included replacing the loose and working rivets with their next larger size. These fasteners were installed “...wet with EA9309 structural adhesive in accordance with Raytheon Aircraft technical support recommendations. (I) recommend this area be looked at closely on Beech 300 aircraft after accumulation of 3000 hours or more.” Fatigue and rudder servo torque were offered as cause for rivet loosening.

Part Total Time: 4,974.1 hours.

 

HELICOPTERS

AUGUSTA

Agusta; A 109E; Cracks in Vertical Stabilizers; ATA 5530

An operator describes finding a 4-inch crack in the leading edge spar doubler of this helicopter’s lower vertical fin. Further inspection reveals two additional cracks in the upper vertical fin with approximate measures of 5 and 7 inches. “(Neither) a detail breakdown of this assembly...(or)...the part numbers of the individual cracked components are available to this operator. The approximate location of the damaged area is station 9141, WL (water line) 1625. This tail boom (P/N 109-0370-17-115) is being returned to the manufacture for repair evaluation.” (See the next entry for similar defects and a mechanical drawing.)

Part Total Time:  1391.6 hours.

 

Agusta; A 119; Cracks in Vertical Stabilizer; ATA 5530

A repair station mechanic submitted a similar defect report as the last entry. He states, “This is to report cracks in the frames on the vertical fin (P/N 109-0373-01) in the areas at W.L. 2145.0 and 2520.0. These cracks are occurring approximately between F.S. 9350.0 to 9850.0. Agusta Aerospace has a repair for these cracks referenced in Agusta A119/A109 Series Structural Repair Manual, Chapters 4-2-23 and 4-2-24.” (The report includes two Agusta manual drawings, both of which have been cropped and spliced together to show stabilizer crack locations in one picture.)


 

 

Part Total Time: 1,205.9 hours.

 

ACCESSORIES

B. F. GOODRICH

B. F. Goodrich; Emergency Power Supply; Improper Battery Cells; ATA 2400

The submitting repair station technician describes finding this aircraft emergency avionic power supply (P/N 501-1228-03) packed full of cells having both the wrong chemistry and voltage. “This unit contains 24 NICAD (nickel cadmium) cells in place of the 12 lead acid cells that belong in it. The higher voltage appears to have burned the cell switch block. NICAD cells are not an approved replacement cell for this unit.” (Two pictures of this unit are shown below. No other information accompanied this submission.)


 

Part Total Time:  unknown.

 


AIR NOTES

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

One of the recent improvements to the Flight Standards Service Aviation Information Internet web site is the inclusion of FAA Form 8010-4, Malfunction or Defect Report. This web site is still under construction and further changes will be made; however, the site is now active, usable, and contains a great deal of information.

Various electronic versions of this form have been used in the past; however, this new electronic version is more user friendly and replaces all other versions. You can complete the form online and submit the information electronically. The form is used for all aircraft except certificated air carriers who are provided a different electronic form. The Internet address is: http://forms.faa.gov/forms/faa8010-4.pdf

When the page opens, select “M or D Submission Form” and, when complete, use the “Add Service Difficulty Report” button at the top left to send the form. Many of you have inquired about this service. It is now available, and we encourage everyone to use this format when submitting aviation, service-related information.

 

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

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

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

 

INTERNET SERVICE DIFFICULTY REPORTING (iSDR) WEB SITE

The Federal Aviation Administration (FAA) Internet Service Difficulty Reporting (iSDR) web site is the front-end for the Service Difficulty Reporting System (SDRS) 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, Mechanical Reliability Reports (MRRs), Malfunction or Defect Reports (M or Ds), or Service Difficulty Reports (SDRs) as they are commonly called, are collected, converted into a common SDR format, stored, and made available to the appropriate segments of the FAA, the aviation community, and the general public for review and analysis. SDR data is accessible through the “Query SDR data” feature on the iSDR web site at: http://av-info.faa.gov/SDRX/ .

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

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

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


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

The SDRS 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:

John Jackson
Service Difficulty Reporting System, Program Manager
Aviation Data Systems Branch, AFS-620
P.O. Box 25082
Oklahoma City, OK 73125
Telephone: (405) 954-6486
SDRS Program Manager e-mail address: 9-AMC-SDR-ProgMgr@faa.gov

 

IF YOU WANT TO CONTACT US

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

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

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

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

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

 

AVIATION SERVICE DIFFICULTY REPORTS

The following are abbreviated reports submitted for the previous month, which have been entered into the FAA Service Difficulty Reporting (SDR) System 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

2005FA0001245

 

 

 

SWITCH

SHORTED

8/18/2005

 

 

 

94E423

HEATER ASSY

FOUND COMBUSTION AIR PRESSURE SWITCH (PN 94E42-3) CLOSED AT ALL TIMES (HAS CONTINUITY). THIS IS A NORMALLY OPEN (N.O.) SWITCH AND CLOSES WHEN IT SENSES AIR PRESSURE AT THE HIGH PRESSURE PORT. WITH IT CLOSED AT ALL TIMES, THIS SAFETY DEVICE WILL TELL THE HEATER THAT IT HAS COMBUSTION AIR, WHETHER ITS THERE OR NOT. NOT GOOD IF THE COMBUSTION AIR BLOWER FAILS. THIS 94E42 SERIES SWITCH DOES NOT REQUIRE INSPECTION IAW AD AT THIS TIME. TO PREVENT REOCCURRENCE, RECOMMEND TESTING THESE COMBUSTION AIR PRESSURE SWITCHES IN CONJUNCTION WITH THE PRESSURE DECAY TEST MANDATED BY AD.

CA050804007

 

 

 

MAGNETO

FAILED

7/25/2005

 

 

 

107902010

ENGINE

MAGNETO SENT TO US TO OFFSET COST OF PARTS ORDERED FROM US. INSPECTION CARRIED OUT PRIOR TO PUTTING UNIT IN STOCK. FOUND RETAINING RING ON DISTRIBUTOR GEAR SHAFT WAS REUSED. DISTRIBUTOR GEAR OF OLD DESIGN, SHOULD BE REPLACED AS PER TCM 53658. MAGNETO WAS OVERHAULED. IMPULSE COUPLING WAS INSPECTED FOR CONDITION/OPERATION. DOES NOT ENGAGE. IMPULSE SPRING WOUND BACKWARDS, DISENGAGING FLYWEIGHTS FROM STOP PINS. STARTING THE ENG WITH THIS MAGNETO MAY CAUSE KICKBACK DUE TO THE ENGINE BEING FIRED AT ITS NORMAL ADVANCED TIMING POSITION, NOT THE RETARDED POSITION THE IMPULSE COUPLING PROVIDES. KICKBACK MAY DAMAGE ENGINE AND ACCY COMPONENTS AND CAUSE FAILURE OF THE ENGINE.

2005FA0001299

 

CONT

 

ROTOR SHAFT

SHEARED

9/15/2005

 

IO240B

 

 

MAGNETO

UNSCHEDULED FAILURE OF THE LT ENGINE MAGNETO DURING ENGINE START. FOUND MAGNETO ROTOR SHAFT SHEARED AT POINTS CAM DRIVE END.

CA050804003

 

CONT

CONT

LINE

CLOGGED

7/7/2005

 

IO470VO

 

 

CRANKCASE

(CAN) EXCESSIVE AMOUNTS OF AN UNIDENTIFIED SEALANT WAS USED ON THE SPLIT-LINE CAUSING THE SEALANT TO SQUEEZE INTO THE ENGINE. A LOSS OF TORQUE WAS FOUND ON THE THRU-BOLTS AND CYLINDER BASE NUTS. THE OIL PICK-UP WAS CLOGGED WITH THE LOOSE SEALANT.

2005FA0001316

 

CONT

 

CYLINDER

BROKEN

9/21/2005

 

O300D

 

SA10200

ENGINE

ENGINE CYLINDER NR 6, CRACKED CIRCUMFERENTIALLY AND FULLY SEPARATED BETWEEN THE 12TH AND 13TH COOLING FINS AS COUNTED FROM THE BASE OF THE CYLINDER CAUSING A COMPLETE LOSS OF ENGINE POWER.

CA050810004

 

LYC  

 

CAMSHAFT

WORN

7/28/2005

 

LIO360C1E6

 

LW11538

ENGINE

(CAN) DURING A ROUTINE INSPECTION, THE OIL FILTER WAS CUT OPEN AND EXAMINED FOR METAL CONTAMINATION IAW MAINTENANCE INSTRUCTIONS. THE FINDINGS WERE TAKEN FOR FURTHER ANALYSIS. IT WAS DETERMINED THAT THE ENGINE WOULD NEED TO COME OFF WITHIN 50 HRS. 28.8 HRS LATER THE ENGINE WAS REMOVED AND SENT FOR REPAIR. ON WO NR 0508026, REPAIRED THE ENGINE, REPLACING AMONG OTHER PARTS THE CAMSHAFT. THE ENGINE WAS THEN REINSTALLED.

CA050223006

 

PWA  

 

CONNECTOR

IMPROPER PART

2/11/2005

 

PT6T3

 

310050401

FUEL 

(CAN) DURING ENGINE VISUAL INSPECTION AT MFG, WE HAVE IDENTIFIED THAT 2 ITEMS FROM THE FUEL PRESSURE TUBING WERE NOT GENUINE AND WERE MANUFACTURED BY AN UNKNOWN SOURCE. THOSE 2 ITEMS HAVE NO IDENTIFICATION NUMBERS BUT WERE INSTALLED IN REPLACEMENT OF: FUEL CONNECTOR P/N 3100499-01 CONNECTOR BOLT P/N 3100504-01 BOTH PARTS ARE KEPT IN QUARANTINE FOR 21 DAYS FOR REVIEW, AFTER WHICH THEY WILL BE DESTROYED. NOTE: THIS IS THE 4TH OCCURRENCE RECENTLY.

CA050223007

 

PWA  

 

CONNECTOR

IMPROPER PART

2/22/2005

 

PT6T3

 

310050401

FUEL 

(CAN) DURING ENGINE VISUAL INSPECTION AT MFG, WE HAVE IDENTIFIED THAT 2 ITEMS FROM THE FUEL PRESSURE TUBING WERE NOT GENUINE AND WERE MANUFACTURED BY AN UNKNOWN SOURCE. THOSE 2 ITEMS HAVE NO IDENTIFICATION NUMBERS BUT WERE INSTALLED IN REPLACEMENT OF: FUEL CONNECTOR P/N 3100499-01 CONNECTOR BOLT P/N 3100504-01 BOTH PARTS ARE KEPT IN QUARANTINE FOR 21 DAYS FOR REVIEW, AFTER WHICH THEY WILL BE DESTROYED. NOTE: THIS IS THE 5TH OCCURENCE RECENTLY.

CA050808004

 

PWC  

 

ENGINE

MAKING METAL

8/1/2005

 

PW150A

 

 

 

(CAN) LOSS OF ENGINE OIL PRESSURE OBSERVED IN CRUISE. ENGINE WAS SHUTDOWN AND UNEVENTFUL SINGLE ENGINE LANDING PERFORMED. GROUND EXAMINATION SHOWED A QUANTITY OF METAL CHIPS ON THE RGB CHIP DETECTOR. ENGINE IS EN-ROUTE TO MFG FOR TEAR-DOWN INVESTIGATION. MFG WILL KEEP INFORMED AS THE INVESTIGATION PROGRESSES.

CA050722002

AEROSP

TMECA

 

FITTING

BROKEN

6/23/2005

SA315B

ARTOUSTE3B

 

 

HORIZONTAL STAB

(CAN) COMPOSITE HORIZONTAL STABILIZER INSTALLED IN ACCORDANCE WITH STC SR00124LA-D. THE R/H REAR ATTACHMENT LUG WAS FOUND TO BE BROKEN COMPLETELY OFF AT THE SPAR ON THE STABILIZER. IT WAS FOUND WHILE A DAILY INSPECTION WAS BEING PERFORMED ON THEAIRCRAFT. WE HAVE INFORMED THE MANUFACTURER WHO HAS ISSUED A SERVICE BULLETIN 05-01.

CA050809001

AIRBUS

GE  

 

SWITCH

SHORTED

8/4/2005

A310300

CF680C2*

 

E0062D1S4BJ04

ANTI COLLISION L

(CAN) DURING STATION TURN AROUND, MAINTENANCE NOTICED SMALL SPARK COMING OUT OF THE ANTI-COLLISION CONTROL SWITCH (2LV). CIRCUIT BREAKER (5LV) OF THE LOWER BEACON WAS POPPED. FOUND THE ANTI-COLLISION SWITCH CONTACTS 1B AND 2B SHORTED TOGETHER, REGARDLESS OF THE SWITCH POSITION AND SHORTED TO GROUND THROUGH THE SWITCH BODY. SWITCH ASSEMBLY WAS REPLACED.

CA050808001

AIRBUS

GE  

 

CIRCUIT BREAKER

BURNED

8/4/2005

A310304

CF680C2*

 

NAS931323501

 

(CAN) DURING ENGINES GROUND RUN AFTER A ROUTINE INSPECTION VISIT, THE FOLLOWING CIRCUIT BREAKERS WERE FOUND POPPED, FUEL LT INNER TANK PUMP NR 1, FUEL RT INNER TANK PUMP NR 2, FUEL CENTER TANK RT PUMP, FUEL LT OUTER TANKPUMP NR 1 AND AFT CABIN FAN. DURING INVESTIGATION FOUND C/B 2XN BURN AND PHASE C MISSING AT 101VUB23 , FOR 202XP BUSS BAR. C/B REPLACED. A SPECIAL INSPECTION CAMPAIGN WAS INITIATED TO PERFORM A DETAIL IN SPECTION OF CIRCUIT BREAKERS INSTALLED IN ALL AIRCRAFT POWER CENTER 101VU AND REPLACE IN CASE OF FINDINGS.

CA050808003

AIRBUS

RROYCE

 

PUMP

FAILED

8/7/2005

A330243

RB211TRENT77

 

9749976

HYD SYSTEM

(CAN) AIRCRAFT RETURNED TO THE STATION DUE TO NR 1 ENGINE LOW HYDRAULIC PRESSURE AND LOSS OF HYDRAULIC FLUID GREEN SYSTEM. DURING INVESTIGATION THE HYDRAULIC PUMP HAD FAILED WITH A HOLE INTO THE HOUSING. HYDRAULIC PUMP AND FILTER REPLACED AND AIRCRAFT WAS RETURN TO SERVICE. PUMP ROUTED TO REPAIR SHOP FOR INVESTIGATION.

2005FA0001255

AMD  

GARRTT

 

SHAFT

SHEARED

7/14/2005

FALCON10

TFE731*

 

41222

DRIVE

WHILE PERFORMING AN ENGINE GROUND OPERATION THE HYDRAULIC PUMP OUTPUT CEASED. A SHEARED PUMP EXTERNAL DRIVE SHAFT WAS DISCOVERED. SYSTEM REGULATION AND RETURN FILTERS AND PUMP HOSES SHOW NO INDICATIONS OF METAL CONTAMINATES. THE PUP STUB SHAFT STILL TURNS BY HAND. REMOVED PUMP ASSEMBLY FROM SERVICE AND INSTALLED AN OVERHAULED PUMP. (K)

2005FA0001254

AMD  

GARRTT

 

TRANSDUCER

FAILED

12/5/2004

FALCON20

TFE731*

 

95426531

ANTI SKID SYS

NORMAL APPROACH WITH A GOOD ANTI-SKID CK, AC WENT OFF END OF 6000 FT WET RUNWAY. INSP OF TIRE MARKS AFTER ACCIDENT, NO EVID OF BRAKING ACTION. NO CAUSE OF FAILURE. ON TEST FLT AFTER REPAIR, RT ANTI-SKID WOULD NOT TEST IN AIR. ANTI-SKID WAS LEFT ON LANDING, BRAKING OPERATED NORMALLY. TAXING AFTER LANDING, RT BRAKES QUIT WORKING WHILE ANTI-SKID WAS ON. LT AND RT BRAKES WORKED NML WHEN ANTI SKID WAS TURNED OFF. TESTED ALL OF ANTI-SKID TRANSMITTERS, FOUND NR 3 TRANSMITTER TO HAVE AN OPEN CIRCUIT IN 70 PERCENT OF ITS TRAVEL. MM TEST SPECIFIES TO HOLD BOTH BRAKE PEDALS, SPIN ONE TRANSDUCER WHICH SHOULD CAUSE ALL BRAKES TO RELEASE. THIS TEST PERFORMED AFTER ACCIDENT, BEFORE TEST FLT, CHECKED OK BOTH TIMES.

2005FA0001224

AMD  

 

 

COVER

MELTED

8/11/2005

FALCON900EX

 

 

200146901

MICROWAVE OVEN

MICROWAVE OVEN, PN 400-1338-02-L, INSTALLED, EXPERIENCED A (SMOKE EVENT) WHILE FLYING OVER TURKEY. REP EXAMINED THE UNIT ON 8/12/2005. THE MOISTURE COVER HAD OVERHEATED DURING OPERATION WITH A LIGHT LOAD. SB-MW-02, DATED 4/25/01 TO REPLACED MOISTURE COVER WAS NOT INSTALLED. RECURRENCE COULD BE PREVENTED BY INSTALLING SB-MW-02. (K)

2005FA0001280

AMD  

GE  

 

SHUTOFF VALVE

INTERMITTENT

8/29/2005

FALCONF

CF700*

 

14632112

P3 

INSTALLED O/H VALVE. PERFORMED LEAK CHECKS OF VALVE WITH NO DEFECTS NOTED. AC NOTED LOW AIRFLOW ON GROUND. OPS CHECKED PRESSURIZATION ON GROUND AND FOUND THAT AC WOULD NOT PRESSURIZE. TROUBLESHOT VALVE AND DETERMINED THAT THE VALVE INSTALLED WAS MALFUNCTIONING. VALVE WOULD ONLY MOVE INTERMITTENTLY. FURTHER REVIEW FOUND THAT THE VALVE WAS PREVIOUSLY O/H DUE TO SAME REASON. NO RECOMMENDATIONS FOR PREVENTING RECURRANCE EXCEPT FOR METHODS AND STANDARDS REVIEW OF THE REPAIR STATION THAT OVERHAULED THE PART. (K)

2005FA0001270

AMTR

LYC  

 

CYLINDER

CRACKED

11/18/2004

AEROSTARBIRD

TIO540*

 

40005401

MLG 

COLLAR SEPARATING FROM TUBE DUE TO INSUFFICIENT PENETRATION WHEN PART WAS FURNACE BRAZED OR SILBER SOLDERED TOGETHER- WORKING COLLAR CAUSED PART TO WORK AND CRACK BOSS. RECOMMEND INSPECTION OF COLLAR AT BOTTOM OF GEAR STRUT FOR ANY MOVEMENT OR WORKING BETWEEN COLLAR AND THE STRUT CYLINDER ASSEMBLY- DYE CHECK COLLAR WHERE PART IS MACHINED FOR CLEARANCE ON TORQUE LINKS. (K)

2005FA0001269

AMTR

LYC  

 

CYLINDER

CRACKED

11/18/2004

AEROSTARBIRD

TIO540*

 

40005401

MLG 

COLLAR SEPARATING FROM TUBE DUE TO INSUFFICIENT PENETRATION WHEN PART WAS FURNACE BRAZED OR SILVER SOLDERED TOGETHER-WORKING COLLAR CAUSED PART TO WORK AND CRACK BOSS. (K)

9132005

AMTR

 

 

STEP

DAMAGED

9/14/2005

LANCAIR

 

 

314 

LT SIDE

RETRACTABLE STEP ASSEMBLY MECHANISM IS ATTACHED TO THE LANDING GEAR STRUT BY A STEEL BRAIDED CABLE WITH METAL CLAMP. CLAMP AROUND STRUT ROTATED ALLOWING EXCESSIVE SLACK IN THE CABLE. WHEN THE LT LANDING GEAR WAS EXTENDED IT CAME IN CONTACT WITH THE RETRACTABLE STEP ASSEMBLY AND WOULD NOT ALLOW THE LANDING GEAR TO LOCK IN THE DOWN POSITION.

CA050818003

BAG  

GARRTT

 

BULKHEAD

CRACKED

8/9/2005

JETSTM3212

TPE33110UG

 

 

NLG WW

(CAN) CRACK ON FRONT PRESSURE BULKHEAD LT VERTICAL WEB, AT LT NOSE GEAR TRUNNION ATTACHMENT BRACKET TOP CENTER BOLT HOLE.

2005FA0001260

BBAVIA

LYC  

 

B-NUT

LOOSE

8/22/2005

7KCAB

IO320*

 

 

CRANKCASE

ENGINE OIL PRESSURE LINE B-NUT AT GEAR CASE LOST TORQUE AND THE ENGINE LOST ALL OIL. LACK OF LUBRICATION CAUSED FAILURE OF THE NR2 CONNECTING ROD BEARING. (K)

CA050819012

BBAVIA

LYC  

 

CONTROL CABLE

FRAYED

8/19/2005

8GCBC

O360C2E

 

19023

TE FLAPS

(CAN) LT AND RT FLAP CABLES FRAYED AT WING ROOT PULLEYS.

CA050819006

BBAVIA

LYC  

 

LEAF SPRING

BROKEN

8/19/2005

8GCBC

O360C2E

 

315435

TAIL WHEEL

(CAN) MAIN LEAF SPRING BROKEN AT ALIGNMENT DIMPLE.

CA050819007

BBAVIA

LYC  

 

CONTROL CABLE

FRAYED

8/19/2005

8GCBC

O360C2E

 

19023

TE FLAPS

(CAN) RT FLAP WING ROOT CABLE FRAYED AT PULLEY.

CA050819008

BBAVIA

LYC  

 

CONTROL CABLE

FRAYED

8/19/2005

8GCBC

O360C2E

 

12364

RUDDER

(CAN) LT RUDDER CABLE FRAYED AT CABIN PULLEY.

CA050819009

BBAVIA

LYC  

 

CONTROL CABLE

FRAYED

8/19/2005

8GCBC

O360C2E

 

12364

RUDDER

(CAN) LT RUDDER CABLE FRAYED AT CABIN PULLEY.

CA050819010

BBAVIA

LYC  

 

CONTROL CABLE

FRAYED

8/19/2005

8GCBC

O360C2E

 

12364

RUDDER

(CAN) LT RUDDER CABLE FRAYED AT CABIN PULLEY.

CA050819011

BBAVIA

LYC  

 

CONTROL CABLE

FRAYED

8/19/2005

8GCBC

O360C2E

 

19023

TE FLAPS

(CAN) RT FLAP CABLE FRAYED AT WING ROOT PULLEY.

CA050812003

BBAVIA

LYC  

 

MOUNT

CRACKED

8/11/2005

8GCBC

O360C2E

 

21583

FLAP HINGE

(CAN) ON THE RT WING IB MOST FLAP MOUNT THERE ARE SEVERAL SMALL CRACKS PROTRUDING OUT OF THE LOWER BOLT HOLE WHICH IS USED TO ATTACH THE BRACKET TO THE REAR SPAR OF THE WING.

CA050812004

BBAVIA

LYC  

 

MOUNT

CRACKED

8/9/2005

8GCBC

O360C2E

 

21583

FLAP HINGE

(CAN) ON THE LT WING IB MOST FLAP MOUNT THERE ARE SEVERAL SMALL CRACKS AND ONE LARGE CRACK PROTRUDING OUT OF THE LOWER BOLT HOLE WHICH IS USED TO ATTACH THE BRACKET TO THE REAR SPAR OF THE WING.

2005FA0001294

BBAVIA

LYC  

 

BEARING

DAMAGED

9/15/2005

8KCAB

AEIO360*

 

 

HORIZONTAL STAB

DURING PREFLIGHT THE PILOT FOUND EXCESSIVE MOVEMENT IN THE LT OB ELEVATOR HINGE PIN. MAINTENANCE REMOVED BOTH ELEVATORS AND THE RUDDER AND FOUND LONGITUDINAL SCORING ON ALL THE HINGE BOLTS (AN23-40) APPARENTLY CAUSED DURING MFG OF THE AIRCRAFT. THE LONGITUDINAL SCORING WAS CAUSED BY THE CENTER NEEDLE BEARING (PN B34PS) ON THE ELEVATOR AND RUDDER. CIRCUMFERENTIAL SCORING WAS ALSO PRESENT ON ALL BOLTS APPARENTLY CAUSED BY IMPROPERLY ALIGNED AND REAMED BUSHINGS (PN 1-3737-1) ON THE HORIZONTAL AND VERTICAL STABILIZER HINGES. THE MFG WAS CONTACTED CONCERNING THE PROBLEM. THE SAME CONDITION IS PRESENT IN SN 943-2004.

CA050823004

BEECH

PWA  

 

WIRE

LOOSE

8/18/2005

100BEECH

PT6A28

 

 

FEED BUSS

(CAN) SUB PANEL RT NR 1 CB POPPED CAUSING MULTIPLE SYSTEM FAILURES. INVESTIGATION FOUND DUAL FEED BUSS HAD AN OPEN. FURTHER INVESTIGATION REVEALED MULTIPLE WIRING ABNORMALITIES FROM POOR MAINTENANCE IN THE PAST, AND ELECTRICAL CONNECTIONS LOOSE FROM AGE.

CA050823006

BEECH

PWA  

 

DOOR

STIFF

8/15/2005

100BEECH

PT6A28

 

 

TAILCONE

(CAN) THE AIRCRAFT WAS PARKED IN HEAVY RAIN WAITING FOR PASSENGERS. DURING CRUSE THE FLIGHT CREW NOTICED ELEVATOR CONTROLS STIFF/ FROZEN. CONTROLS FREED UP DURING DESCENT AS THEY ENTERED WARMER AIR. INVESTIGATION ON THE GROUND FOUND LARGE QUANTITIES OF WATER AND ICE IN THE TAIL NEXT TO THE PRESSURE BULKHEAD. LOW POINT IN THE CABLE RUN AND IN THE TAIL CONE. DETAILED INVESTIGATION FOUND THE DOUBLERS INSTALLED AFTER THE DUAL STRAKE CONVERSION HAD COVERED THE DRAIN HOLES FOR THE TAIL AND TAIL CONE, ALLOWING WATER TO POOL.

CA050726005

BEECH

PWA  

HARTZL

BOLT

LOOSE

7/24/2005

1900C

PT6A65B

 

B3339

PROPELLER

(CAN) DURING AN INSPECTION OF THE BOLTS ACCORDING TO AD2005-14-12 ALL OF THE BOLTS FAILED THE TEST TORQUE.THE BOLTS WERE ALL OF BATCH NUMBER 56.THIS IS ONE OF THEBATCHES THAT IS REQUIRED TO BE REPLACED BY THE AD.THE BOLTS WERE REPLACED.

CA050823003

BEECH

PWA  

 

SKIN PANEL

CORRODED

6/8/2005

1900D

PT6A67D

 

1294300653

PYLON

(CAN) SEVER CORROSION FOUND BETWEEN BONDED MEMBERS OF THE SKIN PANEL ASSY STRETCHING THRU THE ENTIRE LENGTH OF THE PANEL.

CA050802001

BEECH

PWA  

 

TRUSS

CRACKED

5/30/2005

1900D

PT6A67D

 

12991004713

ENGINE MOUNT

(CAN) MULTIPLE CRACKS WERE FOUND EMITTING FROM TOOLING HOLES AND RIVETS IN BRACKETS A (220-050) AND B (220-051), IAW DRAWING NR 129-910047-13.

CA050802002

BEECH

PWA  

 

WIRE

BROKEN

7/31/2005

1900D

PT6A67D

 

 

UPLOCK SWITCH

(CAN) AFTER TAKEOFF ,THE GEAR WAS RETRACTED AND THE RED INTRANSIT LIGHT DID NOT EXTINGUISH. THE GEAR WAS EXTENDED AND OPERATED NORMALLY. THE FLIGHT CONTINUED, THE CREW DID A FLYBY OF TOWER TO CONFIRM GEAR POSITION WHEN UP. THE TOWER THOUGHT THE NOSE WAS LOWER THAN NORMAL. (THE NOSE GEAR TIRE ON A1900 ALWAYS STICKS OUT OF WHEEL WELL.) THE GEAR WAS EXTENDED AND INDICATED SAFELY. THE AIRCRAFT RETURNED TO BASE WHERE MAINTENANCE FOUND A BROKEN WIRE ON THE NOSE GEAR UPLOCK SWITCH HARNESS.

CA050824010

BEECH

PWA  

 

DRIVE ASSY

SHEARED

8/15/2005

1900D

PT6A67D

 

1013800006

TE FLAPS

(CAN) AC HAD JUST LANDED, SELECTED FLAPS UP, STOPPED BETWEEN APPROACH AND ZERO (FULL UP). PILOT CALLED MAINT, WAS INSTRUCTED TO TRY SPLIT FLAP BYPASS SYS, INFORMED MAINT THAT ALL FLAPS WENT UP EXCLUDING THE RT OB. ASSUMED THAT FLAP DRIVE CABLE WAS SHEARED. AME`S WERE SENT TO INSPECT SYS, CONFIRMED SHEARED CABLE. RT FLAP WAS SECURED IN FULL UP POSITION, FLAP SYS DEFERRED AND AC WAS FLOWN BACK TO MAIN MAINT FACILITY. AFTER CABLE WAS REPLACED ALL NECESSARY CHECKS WERE COMPLETED, NO OTHER FAULTS WERE FOUND. CAUSE OF CABLE FAILURE WAS CORROSION DUE TO TRAPPED MOISTURE. UPON FURTHER INVESTIGATION OF RECORDS IT TURNS OUT THAT CABLE WAS THE NEWEST OF THE 3 CABLES INSTALLED. MFG HAS BEEN NOTIFIED, PICTURES SENT.

CA050803006

BEECH

PWA  

 

DRIVE SHAFT

SHEARED

8/2/2005

1900D

PT6A67D

 

 

ACTUATOR

(CAN) ON CLIMBOUT, ELEC TRIM WAS OPERATED, IT WOULD ONLY MOVE 1.5 DEG FROM FULL NOSE UP, COULD NOT BE MOVED MANUALLY. AC RETURNED TO DEPARTURE AIRPORT. ELEV TRIM WAS STILL JAMMED ON GROUND ELECTRICALLY AND MANUALLY. INSP OF ACTUATOR MOTOR, IN TAIL SECTION, REVEALED THAT DRIVE HAD SHEARED AT END OF ACTUATOR. ACTUATOR IS CONNECTED TO ANOTHER CABLE DRUM UNIT WITH UNIVERSAL JOINT. ACTUATOR ASSY IS CONNECTED TO 1 ELEV TRIM CABLE WITH BRIDAL CABLE, DRUM UNIT IS CONNECTED TO OTHER ELEV TRIM CABLE WITH A BRIDAL CABLE. WHEN ACTUATOR DRIVE SHEARED, BRIDAL CABLE OF DRUM UNIT AND UNIVERSAL JOINT JAMMED ELEVATOR TRIM CABLE, SO THERE WAS VERY LITTLE MOVEMENT OF TRIM SYS. REASON FOR ACTUATOR DRV BREAKING IS UNKNOWN.

R017794

BEECH

PWA  

HARTZL

BEARING

BROKEN

9/20/2005

1900D

PT6A67D

HCE4A3J

D7745

PROPELLER HUB

PROP WAS REMOVED FOR LOOSE BLADE. PROP WAS OVERHAULED BY MFG SERVICE CENTER ON 10/7/03 AND INSTALLED NEW D-7745 BEARINGS AT THAT TIME. HUB SIDE BEARINGS ON BLADES 2 AND 3 ARE CRACKED CIRCUMFERENTIALLY. HUB SIDE BEARING ON BLADE 4 IS BROKEN.

CA050816003

BEECH

PWA  

 

DRIVE GEAR

BROKEN

7/16/2005

200BEECH

PT6A41

 

311663301

A/C PACK

(CAN) FOLLOWING FLIGHT AND DURING A LAYOVER CHECK, IT WAS NOTED THAT AIR CONDITIONING ACCY DRIVE WAS DE-COUPLED FROM GAS GENERATOR AS NOTED DURING ROTATION OF AC COMPRESSOR. REMOVAL OF EXTERNAL DRIVE SPLINE DETERMINED THAT THE FAULT WAS NOT EXTERNAL TO ENGINE BUT RATHER ISOLATED TO INTERNALS OF ENGINE ACCY GB. ENGINE WAS REMOVED, SENT TO AN ENGINE SHOP FOR INVESTIGATION AND REPAIR. ENGINE TEARDOWN DETERMINED THAT DE-COUPLING WAS RESULT OF BROKEN AGB OPTIONAL GEAR, WHICH DRIVES AC COMPRESSOR. ROOT CAUSE OF PROBLEM WAS A RESTRICED OIL JET NOZZLE CAUSING ABNORMAL SHAFT SPLINE WEAR, WHICH RESULTED IN ABNORMAL PLAY AND ROTATION OF THE AGB COUPLING SHAFT, RESULTING FATIGUE FAILURE OF THE AGB OPTIONAL GEAR.

CA050811003

BEECH

PWA  

 

WINDSHIELD

DELAMINATED

8/8/2005

200BEECH

PT6A41

 

10138402521

COCKPIT

(CAN) DURING DESCENT THE PILOTS WINDSHIELD COMPLETELY DELAMINATED. THE WINDSHIELD STAYED IN PLACE HOWEVER THE VISION FORWARD WAS COMPLETELY OBSCURED.

2005FA0001246

BEECH

 

 

CONNECTOR

LOOSE

8/15/2005

400A

 

 

3446J1B

WIRE BUNDLE

INVESTIGATED IN-FLIGHT (GPWS), (TERR), AND (WINDSHEAR) FAILE INDICATIONS. SYSTEM FAILURES CONFIRMED ON GROUND. FOUND AIRFRAME WIRING CONNECTOR (3446J1B UNSEATED FROM EGPWS UNIT CONNECTOR DUE TO TENSION ON WIRING BUNDLE. RESEATED CONNECTOR PINS AND RESECURED WIRING BUNDLE AS REQUIRED TO RELIEVE TENSION. REINSTALLED CONNECTOR TO EGPWS UNIT, OPS CHECK OK. (K)

2005FA0001282

BEECH

PWA  

 

SWITCH

FAILED

8/17/2005

400A

JT15D5

 

5EN16

NLG 

LANDING GEAR SYS RED (GEAR UNSAFE) WARNING LIGHT REMAINED ILLUMINATED FOLLOWING GEAR EXTENSION WHILE LANDING. ALL (3) GREEN LANDING GEAR DOWN AND LOCKED POSITION INDICATING LIGHTS ILLUMINATED. AC FERRIED FOR REPAIRS. FOUND LT MLG DOOR POSITION SWITCH S097 FAILED INTERNALLY. REPLACED S097 SWITCH ASSY WITH SERVICEABLE UNIT, LANDING GEAR RETRACT/EXTENSION SYSTEM TESTS NORMAL. TRANSIENT AIRCRAFT, UNABLE TO DETERMINE TT ON FAILED SWITCH. SUGGEST THAT LG POSITION INDICATING SWITCHES BE SCHEDULED REPLACEMENT ITEMS. PROBABLY IN CONJUNCTION WITH LANDING GEAR 7400 HR/5000 CYCLE INSPECTIONS. SUGGEST REPLACING POSITION SWITCHES WITH IMPROVED HERMETICALLY SEALED TYPE SWITCHES AS THEY REQUIRE REPLACEMENT. (K)

2005FA0001267

BEECH

LYC  

 

MOUNT

CRACKED

8/25/2005

77  

O235L2C

 

-71 

ENGINE

THE UPGRADED ENGINE MOUNT WAS FOUND CRACKED. A PLUG USED TO RELIEVE WELDING PRESSURE AND ADD ADD LINSEED OIL APPEARS TO THE THE PROBLEM (STRESS RISER? ETC) THE LINSEED OIL ESCAPED AND MADE A PERFECT CRACK INDICATION WITHOUT USE OF DYE PENETRANT. THE OLDER STYLE, -1 MOTOR MOUNT DOES NOT HAVE PLUGS IN THIS AREA. (K)

CA050617007

BEECH

CONT

 

DOUBLER

CRACKED

6/15/2005

95B55

IO470L

 

5840083S

FRONT WING SPAR

(CAN) DURING ROUTINE LPI INSPECTION OF THE FRONT WING SPAR CARRY THRU STRUCTURE AND REPAIR DOUBLERS IN ACCORDANCE WITH AD90-08-14, THE LT FWD REPAIR DOUBLER WAS FOUNDCRACKED IN THE LOWER BEND RADIUS IN THE SAME SPOT AS THE ACTUAL WING SPAR WHICH THE DOUBLER WAS USED TO REPAIR. THE FAA WAS CONTACTED FOR A REPAIR PROCEDURE AN D ADVISED US THAT REPLACEMENT OF THE DOUBLER WAS AN ACCEPTABLE REPAIR TO RESTORETHE STRUCTURAL INTEGRITY. THE ORIGINAL REPAIR DOUBLER WAS INSTALLED AUGUST 14,1990 AND HAS SINCE ACUMULATED 7486.0 HOURS SINCE IT'S INSTALLATION.

CA050802004

BEECH

PWA  

 

NUT  

LOOSE

8/27/2004

A100

PT6A28

 

MS21042L4

LT PROPELLER

(CAN) AFTER TAKE OFF, THE CREW NOTICED THE LT ENGINE TORQUE WAS OVER RED LINE, POWER WAS REDUCED. MAINTENANCE LATER DISCOVERED THAT PART OF THE LOW PITCH ARM WAS BROKEN OFF. IT WAS DETERMINED THAT THE NUT PN MS21042L4 HOLDING THE PIN PN 100-960036-1 HAD BECOME LOOSE AND THIS ALLOWED THE LOW PITCH ARM TO CONTACT THE PROP BULKHEAD AND BREAK OFF. THE POWER SECTION WAS REPLACED FOR LIGHT OVERHAUL.

CA050829003

BEECH

PWA  

 

BULKHEAD

CRACKED

8/25/2005

A100

PT6A34

 

 

FUSELAGE

(CAN) DURING THE CONTINUING AIRWORTHINESS STRUCTURAL INSPECTION CHAFFING DAMAGE WAS FOUND ON THE AFT SIDE OF THE AFT PRESSURE BULKHEAD. THE LOWER CENTER AND THE LOWER RT INTERCOSTALS RUBBING ON THE BULKHEAD DURING PRESSURIZATION CAUSED THE DAMAGE. FURTHER INVESTIGATION (EDDY CURRENT) FOUND THAT THE BULKHEAD WAS CRACKED AT THE CENTER INTERCOSTAL LOCATION.

CA050829001

BEECH

PWA  

 

DOUBLER

CRACKED

8/25/2005

A100

PT6A34

 

5042002847

FRAME

(CAN) DURING THE CONTINUING AIRWORTHINESS STRUCTURAL INSPECTION A CRACK WAS FOUND IN THE FLOOR LEVEL DOUBLER FOR THE LT FRAME AT FUSELAGE STATION 207.00, THE CRACK MOVED LATERALLY ACROSS THE DOUBLER FROM THE IB SIDE THOUGH 2 RIVET HOLES AND A BEND. THE PROBABLE CAUSE IS THAT THE DOUBLER HAD A PILOT HOLE THAT WAS DIRECTLY ADJACENT TO A RIVET HOLE WITH NO EDGE DISTANCE. THE CRACK WAS ABOUT 3.5 INCHES LONG.

CA050727007

BEECH

 

BEECH

SKIN

CORRODED

7/26/2005

B100

 

 

991300009

AILERON

(CAN) CORROSION WAS FOUND ON THE LEFT HAND AILERON UNDER THE STATIC WICKS. THE AILERO N WAS REMOVED AND DISASSEMBLED. AFTER REMOVING THE UPPER SKIN, IT WAS DISCOVEREDTHAT THE UPPER AND LOWER SKINS WERE CRACKED IN MULTIPLE LOCATIONS, JUST AFT OFTHE JOINT WHERE THE NOSE SKIN OVER LAPS THE AFT SKIN. RAYTHEON HAS PUBLISHED A S.B. TO INSPECT THE RIGHT HAND AILERON FOR CRACKS IN THE SAME LOCATION,BUT NOT FOR THE LT AILERON.

CA050727008

BEECH

 

BEECH

SKIN

CRACKED

7/25/2005

B100

 

 

991300009

AILERON

(CAN) CORROSION WAS FOUND ON THE LEFT HAND AILERON UNDER THE STATIC WICKS. THE AILERO N WAS REMOVED AND DISASSEMBLED. AFTER REMOVING THE UPPER SKIN, IT WAS DISCOVEREDTHAT THE UPPER AND LOWER SKINS WERE CRACKED IN MULTIPLE LOCATIONS, JUST AFT OFTHE JOINT WHERE THE NOSE SKIN OVER LAPS THE AFT SKIN. RAYTHEON HAS PUBLISHED A S.B. (SB57-3148) TO INSPECT THE RIGHT HAND AILERON FOR CRACKS IN THE SAME LOCATION,BUT NOT FOR THE LEFT AILERON.

CA050727009

BEECH

 

BEECH

SKIN

CRACKED

7/25/2005

B100

 

 

991300009

AILERON

(CAN) CORROSION WAS FOUND ON THE LEFT HAND AILERON UNDER THE STATIC WICKS. THE AILERO N WAS REMOVED AND DISASSEMBLED. AFTER REMOVING THE UPPER SKIN, IT WAS DISCOVEREDTHAT THE UPPER AND LOWER SKINS WERE CRACKED IN MULTIPLE LOCATIONS, JUST AFT OFTHE JOINT WHERE THE NOSE SKIN OVER LAPS THE AFT SKIN. RAYTHEON HAS PUBLISHED A S.B. (SB57-3148) TO INSPECT THE RIGHT HAND AILERON FOR CRACKS IN THE SAME LOCATION,BUT NOT FOR THE LEFT AILERON.

CA050817004

BEECH

GARRTT

 

INDICATOR

SMOKE

6/26/2005

B100

TPE3316252B

 

2591411444

FLT DIRECTOR

(CAN) ON TAKEOFF THE FLIGHT DIRECTOR INDICATOR STARTED TO SMOKE. THE PILOT RETURNED TO THE AIRPORT AND LANDED WITHOUT INCIDENT. THE FLIGHT DIRECTOR INDICATOR WAS REMOVED AND A LOANER UNIT WAS INSTALLED. THE AIRCRAFT DEPARTED AND COMPLETED THE FLIGHT WITHOUT FURTHER INCIDENT. A FAULTY POWER TRANSFORMER AND BURNED POWER SUPPLY BOARD WERE REPLACED AND THE UNIT WAS REINSTALLED IN THE AIRCRAFT.

CA050824012

BEECH

GARRTT

 

TORQUE TUBE

CRACKED

8/3/2005

B100

TPE3316252B

 

115610010325

ELEVATOR

(CAN) WHILE CARRYING OUT A PHASE 2 AND 3 INSPECTION, THE RT ELEVATOR TORQUE TUBE HAD A .5 INCH CRACK. THE CRACK WAS DISCOVERED BETWEEN THE ELEVATOR AND TORQUE TUBE. THE TORQUE TUBE WAS REPLACED.

CA050810002

BEECH

PWA  

 

HEATER

FAILED

8/8/2005

B200

PT6A42

 

10585J

FUEL/OIL

(CAN) PILOT REPORTED RT ENGINE HAD NO ACCELERATION RATE AS COMPARED TO LT ENGINE. THE RT ENGINE DID EVENTUALLY ACCELERATE, BUT NOT EQUAL WITH THE LT. TROUBLESHOT AND FOUND RT OIL-TO-FUEL HEATER THERMOSTAT GONE TO (FULL HOT) AND FUEL TEMP WAS SAME AS OIL TEMP, THEREFORE BOILING THE FUEL AND VAPOURIZING IT AND THEREFORE SUBSEQUENT LOSS OFF POWER AND ACCELERATION. OIL TO FUEL HEATER CHANGED AND ACCELERATION REGAINED. THE FUEL CONTROL UNIT WAS CHANGED INITIALLY FOR TROUBLESHOOTING AS OIL TO FUEL HEATER WAS NOT SUSPECTED AS FAULT.

CA050815001

BEECH

PWA  

 

BLOWER

FAILED

8/14/2005

B300B350C

PT6A60A

 

1013841761

FWD CABIN

(CAN) THE AIRCRAFT WAS ON THE RETURN LEG OF A TRIP WHEN THE FORWARD VENT MOTOR P/N 101-384176-1 MODEL EM640-1 FAILED ON SHORT FINAL LANDING. THE TBO ON THIS UNIT IS 1500 HRS IAW COMPONENT OVERHAUL MANUAL. OUR UNIT FAILED PRIOR TO THIS LIMIT AND HAVE HAD OTHER OCCURRENCES OF PREMATURE FAILURE. HAVE DECIDED TO REDUCE THE TBO TIME IN HOUSE TO 1200 HRS AS A PREVENTIVE MEASURE. THE REMOVAL AND INSTALLATION OF THIS UNIT IS A TIME CONSUMING TASK ON THIS AIRCRAFT.

CA050615008

BEECH

PWA  

 

TORQUE TUBE

CRACKED

6/4/2005

B99  

PT6A27

 

115610010191

ELEVATOR

(CAN) UPON REMOVAL OF AIRCRAFT TAILCONE FOR OTHER MAINTENANCE, LT ELEVATOR TORQUE TUBE WAS DISCOVERED CRACKED. CRACK PROPAGATED FROM UNDER ELEVATOR MOUNTING FLANGE FITTING, EMANATING FROM TAPER PIN HOLE. WITH TAPER PINS REMOVED AND FITTING SLID BACK, ONLY THEN COULD FULL EXTENT OF DAMAGE BE VIEWED. CRACK STARTED AT IB OF 2 TAPER PINS, SPIRALED BOTH DIRECTIONS COMPLETELY ENCIRCLING TORQUE TUBE. BOTH CRACKS ENDED ABOUT 2 INCHES APART BUT ADJACENT TO EACH OTHER. SMALLER CRACKS WERE ALSO STARTING TO EMANATE FROM TAPER PIN HOLES FOR HORN FLANGE. SB HAD NOT YET BEEN COMPLETED ON THIS ASSY AS IT HAD JUST 364.7 HRS SINCE NEW . THIS DAMAGE MAY HAVE BEEN CAUSED BY SEVERE GUST LOADS OR JET BLAST.

2005FA0001315

BEECH

PWA  

 

DOWNLOCK SWITCH

OUT OF ADJUST

9/23/2005

C90  

PT6A21

 

 

RT MLG

ON APPROACH THERE WAS NO RT MAIN GEAR INDICATION. CHECKED GEAR RIGGING AND ADJUSTED RT DOWNLOCK SWITCH IAW M/M.

2005FA0001292

BEECH

LYC  

 

CYLINDER

DAMAGED

9/9/2005

E18S

IO540*

 

LW12988

NR 1 

DURING ANNUAL INSPECTION, IT WAS DISCOVERED DURING A DIFFERENTIAL COMPRESSION CHECK THAT THE NR 1 CYLINDER ON THIS ENGINE HAD ALMOST NO COMPRESSION. IT WAS DISCOVERED THAT THE EXHAUST VALVE GUIDE WAS BAD. ALSO, THE EXHAUST VALVE AND INTAKE VALVE HAD TO BE REPLACED. THIS CYLINDER WAS ON AN ENGINE THAT HAD BEEN RECALLED FOR THE CRANKSHAFT REPLACEMENT AD AND HAD ALL CYLINDERS REPLACED AT THAT TIME. THE CYLINDER HAD 149 HOURS IN SERVICE SINCE NEW. MFG WAS NOTIFIED OF THIS PROBLEM BUT WAS NOT INTERESTED. THE CYLINDER WAS REPAIRED.

2005FA0001265

BEECH

CONT

 

NOZZLE

BROKEN

8/23/2005

F33A

IO520BB

 

627335D13A

ENGINE FUEL

ON ROUTINE PHASE INSPECTION THE FUEL INJECTOR NOZZLES WERE REMOVED FOR CLEANING, AT THIS TIME THE MECHANIC DIDN’T NOTICE ANY DEFECTS. THE NOZZLES WERE THEN PLACED IN A CLEANING TANK AND AFTER REMOVING THEM FROM THE TANK THE MECHANIC NOTICED THE RING THAT THE FUEL INJECTOR LINE SEATS TO WAS BROKEN AWAY FROM THE NOZZLE, RECOMMENDATION AT THIS TIME IS TO DO A THROUGH INSPECTION OF THE NOZZLES WHEN THEY ARE REMOVED FOR CLEANING.

CA050729001

BEECH

CONT

 

RIB  

CORRODED

7/28/2005

N35  

IO470N

 

3565000525

STAB 

(CAN) RT STABILIZER END RIB FOUND TO HAVE INTERGRANULAR CORROSION WHERE IT ATTACHED TO THE FORWARD RIB. CORROSION IS ON THE UPPER INSIDE CORNER OF THE RIB AND ONLY CAN BE VIEWED USING SMALL MIRROR THRU THE LIGHTENING HOLE OF THIS RIB JUST IB OF THE RUDDERVATOR BALANCE WEIGHT.

CA050729002

BEECH

CONT

 

RIB  

CORRODED

7/28/2005

N35  

IO470N

 

3565000525

STABILIZER

(CAN) LT STABILIZER END RIB FOUND TO HAVE INTERGRANULAR CORROSION WHERE IT ATTACHED TO THE FORWARD RIB. CORROSION IS ON THE UPPER INSIDE CORNER OF THE RIB AND ONLY CAN BE VIEWED USING SMALL MIRROR THRU THE LIGHTENING HOLE OF THIS RIB JUST IB OF THE RUDDERVATOR BALANCE WEIGHT.

CA050822007

BEECH

CONT

 

ALTERNATOR

FAILED

8/5/2005

V35B

IO520BA

 

ALX9424

ENGINE

(CAN) THE ALTERNATOR REAR BEARING FAILED ALLOWING THE ROTOR TO TOUCH THE FIXED COIL WHICH GENERATED ENOUGH HEAT TO BURN THE PAINT ON THE COIL. AN ODOR WAS NOTICED IN THE CABIN.

CA050816006

BELL

LYC  

 

MOUNT

CRACKED

8/12/2005

205A1

T5317A

 

205060105001

ENGINE

(CAN) THE ENGINE MOUNT WAS MODIFIED BY STC SH99-11 WHICH ALLOWS THE MOUNT TO BECOME ADJUSTABLE. THE ADJUSTABLE PORTION OF THE MOUNT IS RIVETED TO ONE LEG AND IT CRACKED FROM ONE OF RIVET HOLES SECURING THE ADJUSTABLE TURNBARREL TO THE MOUNT LEG.

CA050816005

BELL

LYC  

 

MOUNT

CRACKED

8/12/2005

205A1

T5317A

 

205060105001

ENGINE

(CAN) THE ENGINE MOUNT WAS MODIFIED BY STC SH99-11 WHICH ALLOWS THE MOUNT TO BECOME ADJUSTABLE. THE ADJUSTABLE PORTION OF THE MOUNT IS RIVETED TO ONE LEG AND IT CRACKED FROM ONE OF RIVET HOLES SECURING THE ADJUSTABLE TURN BARREL TO THE MOUNT LEG.

CA050616009

BELL

ALLSN

 

STARTER GEN

FAILED

5/16/2005

206B

250C20

 

23032018

ENGINE

(CAN) NOISE IN HEADSET REPORTED BY PILOT, THAT WAS GETTING WORSE. PILOT TURNED OFF GENERATOR AND NOISE WAS ELIMINATED. STARTER THEN FAILED TO ROTATE WHEN STARTER ATTEMPTED. START/GEN REPLACED AND A/C RETURNED TO SERVICE.

CA050616006

BELL

ALLSN

 

TRANSMITTER

UNSERVICEABLE

6/11/2004

206B

250C20

 

EA4703587

FUEL INDICATOR

(CAN) FUEL QUANTITY INDICATION FLUCTUATES AT NEAR FULL FUEL LEVELS. UPPER SENDING UNIT REPLACED. THIS INSTALLATION WAS 249.9 HOURS.

CA050808002

BELL

ALLSN

 

PUMP

FAILED

8/7/2005

206B

250C20

 

 

ENGINE

(CAN) AIRCRAFT WAS HAVING PROBLEM WITH INITIAL START. FUEL CHECK VALVE AND FCU HAD BEEN CHANGED FOR TROUBLESHOOTING. REPLACED ENGINE DRIVEN FUEL PUMP, AIRCRAFT RETURNED TO SERVICE.

CA050810003

BELL

ALLSN

 

COMBUSTION LINER

CRACKED

7/31/2005

206B

250C20

 

6870992

ENGINE

(CAN) THE PILOT WAS EXPERIENCING HIGH TOT (WITHIN FLIGHT MANUAL LIMITATION) AND REPORTED THAT THE AIRCRAFT WAS FAILING THE POWER CHECK. THE ENGINEER VISUALLY INSPECTED THE ENGINE FOR DISCREPENCIES AND FOUND A 2 INCH CRACK IN THE ARM PIT OF THE OUTER COMBUSTION LINER. TSN OF COMBUSTION LINER UNKNOWN. AIRCRAFT HAS ABOUT 12,950 HOURS ON IT BUT THE COMBUSTION LINER DOES NOT APPEAR TO BE ORIGINAL.

CA050616008

BELL

ALLSN

 

SEAL

WORN

7/27/2004

206B

250C20B

 

406340104101

ENG TO XMSN

(CAN) FORWARD PTO SEAL REMOVED DUE TO OIL TRANSFER FROM ENGINE TO TRANSMISSION. UPON SEAL REMOVAL IT WAS FOUND THE IB SEAL LIP HAD BEEN FOLDED UNDER THE SEAL AT 2 LOCATIONS, APPROXIMATELY 1 INCH EACH. THE TENSION SPRING FROM THE SEAL HAD STAYED ON THE SEAL, A BARELY DETECTABLE WEAR POINT WAS CREATED AT THIS LOCATION. THIS WEAR POINT IS APPROXIMATELY 0.030 INCH FROM THE RUNNING SURFACE OF THE SEAL. ALSO FOUND AT SEAL REMOVAL WAS TWO OTHER TENSION SPRINGS BEHIND THE SEAL, THERE WAS NO DETECTABLE DAMAGE NOTED FROM THESE SPRINGS. NEW SEALS INSTALLED FORWARD AND AFT POSITIONS, A/C GROUND RUN, LEAK CHECKED AND RETURNED TO SERVICE.

CA050725002

BELL

ALLSN

 

BLADE

DAMAGED

7/24/2005

206B

250C20B

 

206010200133

MAIN ROTOR

(CAN) MAIN ROTOR BLADES P/N 206-010-200-133 S/N A6716 AND A6778 WILL NOT FLY LOWEST IPS WAS 1.7 WITH MAXIMUM TABING. THESE ARE NEW BLADES WITH AN APPARENT MANUFACTURING DEFECT.

CA050817001

BELL

ALLSN

 

WINDOW

FAILED

6/28/2005

206L

250C20B

 

206559258

CABIN

(CAN) RETAINER FOR SHOOTING WINDOW FAILED AND VERTICAL SLIDER DEPARTED THE AIRCRAFT. WINDOW REPLACED, A/C INSPECTED, NO FURTHER DAMAGE FOUND.

CA050616005

BELL

ALLSN

BELL

SWITCH

UNSERVICEABLE

3/8/2005

206L

250C20B

 

206063613003

LOW FUEL SWITCH

(CAN) SYSTEM TEST CARRIED OUT AS PART OF THE ANNUAL FUEL SYSTEM INSPECTION. FOUND THAT THE LOW FUEL LIGHT WOULD NOT COME ON UNTIL 25 LBS INDICATED (SHOULD BE 70 LBS). LOW FUEL SWITCH REPLACED AND A/C RETURNED TO SERVICE.

CA050617004

BELL

ALLSN

 

SEAL

LEAKING

5/27/2005

206L

250C20R2

 

206340104101

FREEWHEEL UNIT

(CAN) REPLACED SEAL DUE TO LEAKING OIL. (FREEWHEEL)

CA050804001

BELL

ALLSN

ALLSN

NOZZLE

CRACKED

7/30/2005

206L1

250C28B

 

6896024

COMPRESSOR

(CAN) EJECTOR NOZZLE BROKE OFF INTO THE INTAKE PLENUM AND EVENTALLY WERE DRAWN INTO THE COMPRESSOR.

CA050804004

BELL

ALLSN

 

FITTING

CRACKED

7/22/2005

206L1

250C30

 

2060313293

TAILBOOM

(CAN) A CRACK STARTED AT THE TOP OF THE FITTING AND TRAVELED VERTICALLY THROUGH A RIVET HOLE TO APPROXIMATELY .1250 INCH BELOW IT.

CA050816007

BELL

ALLSN

 

DRIVE SHAFT

WORN

8/14/2005

206L1

250C30P

 

206076373001

MAIN ROTOR TACH

(CAN) WHILE A/C IN CRUSE FLIGHT LOW ROTOR HORN CAME ON. ROTOR RPM INDICATED (0). WHEN PILOT LOWERED COLLECTIVE, HE HAD NO HYDRAULIC PRESSURE. A/C LANDED AND MAIN ROTOR CONTACTED TAILBOOM. ON REMOVAL ROTOR TACH GEN DRIVE SHAFT INTERNAL SPLINES WERE FOUND TO BE WORN TO THE POINT OF DISENGAGEMENT.

CA050804002

BELL

ALLSN

 

BLADE

DAMAGED

6/29/2004

206L3

250C30P

 

206016201131

TAIL ROTOR

(CAN) UPON PILOT DAILY INSPECTION DAMAGE NOTED TO T/R BLADE ASSY. BLADE ASSY VISUALLY INSPECTED AND FOUND DAMAGED BEYOND ACCEPTABLE LIMITS. BLADE REPLACED.

CA050616007

BELL

PWA  

 

WASHER

UNSERVICEABLE

5/1/2004

212  

PT6T3

 

204030913005

XMSN MOUNT

(CAN) CONICAL WASHER FOR TRANSMISSION MOUNT BOLT - LT AFT POSITION - FOUND CRACKED. CRACK HAD NOT TRAVELLED COMPETELY THROUGH WASHER, IT HAD STARTED AT OUTBOARD EDGE. WASHER REPLACED.

2005FA0001303

BELL

ALLSN

 

WIRE

FAILED

9/7/2005

430  

250C40B

 

430076506109

BATTERY

A LOOSE CONNECTION AT THE RING TERMINAL ON THE AIRCRAFT BATTERY CONNECTOR CAUSED SUFFICIENT HEAT BUILDUP TO MELT THE SECURING NUT AND WASHER AND CHAR THE WIRING. THE PROBLEM WAS COMPOUNDED BY THE AIRCRAFT MFG USE OF IMPROPERLY SIZED RING TERMINALS AT THIS CONNECTION. THE MS25036-127 TERMINAL ENDS SPECIFIED BY THE MFG, UTILIZE A (.4375 INCH) HOLE IN CONJUNCTION WITH (.2500 INCH) STUDS ON THE BATTERY CONNECTOR PN MS25182-2. THIS IS CONTRADICTORY TO STANDARD PRACTICE AS SPECIFIED IN AC. (K)

CA050819003

BOEING

PWA  

 

REGULATOR

UNSERVICEABLE

8/16/2005

727247

JT8D15

 

69187094

AC SYSTEM

(CAN) AIRCRAFT EXPERIENCED LOSS OF NR 1 GENERATOR SYSTEM ON APPROACH. THE FLAP INDICATION SYSTEM INDICATED A FLAP OUT OF ASYMMETRIC CONDITION CA USING THE CREW TO ABORT THE LANDING AND DECLARE AN EMERGENCY. THE AIRCRAFT LANDED SAFELY ON SECOND APPROACH AND TAXIED TO THE RAMP. MAINTENANCE DISCOVERED THAT THE NR 1 GENERATOR SYSTEM VOLTAGE REGULATOR HAD FAILED. BY THE NR 1 GENERATOR SYSTEM FAILURE, THIS CAUSED A ERRONEOUS FLAP ASYMMETRY FAULT. THE NR 1 VOLTAGE REGULATOR WAS SWAPPED WITH THE APU VOLTAGE REGULATOR AND THE APU VOLTAGE REGULATOR SYSTEM WAS MEL'D. ALL SYSTEMS CHECKED SERVICEABLE AND THE AIRCRAFT WAS RETURNED TO SERVICE.

CA050826004

BOEING

CFMINT

 

DISPLAY

FAILED

8/25/2005

737*

CFM567B22

 

50401100003

ENTERTAIN SYS

(CAN) ON AUGUST 25, 2005 A/C WAS IN CRUISE WHEN THE CREW WAS ADVISED THAT THE VDU AT SEAT 22B WENT BLANK WITH THE SMELL OF SMOKE. THE IFE SYSTEM WAS TURNED OFF. MAINTENANCE REPLACED THE VDU AND THE SYSTEM TESTED SERVICEABLE. THIS COMPONENT WILL BE RETURNED TO THE MANUFACTURER AND A COMPLETE TEARDOWN REPORT WILL BE REQUESTED. THIS SDR WILL BE UPDATED ONCE THAT INFORMATION IS AVAILABLE.

CA050810001

BOEING

PWA  

 

PITOT SYSTEM

FOD  

8/10/2005

737201

JT8D9A

 

 

PITOT/STATIC SYS

(CAN) ON TAKEOFF ROLL, NO AIRSPEED INDICATION ON THE CAPTAINS SIDE. DEBRIS FOUND IN CAPTAINS UPPER LT PITOT TUBE. BUG REMOVED AND PITOT/STATIC SYSTEM TESTED SERVICEABLE. TIMES: 63714:40 CYCLES: 61165.

CA050815005

BOEING

PWA  

 

FAN  

VIBRATION

8/8/2005

737204

JT8D15

 

 

ENGINE

(CAN) NOTICED, FELT VIBRATION ON INITIAL CLIMB OUT BELOW 10000 FT, BROUGHT UP ENG PARAMETERS ON MFD/VIB AT 3.5/ADVSD MTC. CONTROL/VIB. INCREASED GRADUALLY TO EXCEED 4.0 THROUGH 20000 FEET. AIRCRAFT RETURNED TO DEPARTURE. ENGINE FAN BLADES WERE RE-INSTALLED. ACCORDING TO BLADE SOLUTION DISTRIBUTION. SPINNER CONE WEIGHTS MORMALIZED AND ENGINE RUN CARRIED OUT WITH GOOD RESULTS. ENGINE VIBES NOW 0.2 NO FURTHER DIFICULTIES RECORDED TO DATE. ISSUE CLOSED.

CA050804009

BOEING

CFMINT

 

TORQUE TUBE

WORN

7/27/2005

737522

CFM563C1

 

694020512

TE FLAPS

(CAN) DURING ROUTINE INSPECTION THE NR 2 TRANSMISSION TORQUE TUBE, A DEEP 'V' GOUGE .016 INCH DEEP WAS FOUND. A FLEET CAMPAIGN WAS INITIATED TO CHECK ALL TRAILING EDGE FLAP TORQUE TUBES.

CA050817002

BOEING

CFMINT

 

DISPLAY

SMOKE

8/16/2005

73776N

CFM567B22

 

50401100003

SEAT 21D

(CAN) ON AUGUST 16, 2005 AIRCRAFT WAS IN CRUISE WHEN THE CREW WAS ADVISED THAT THE VDU AT SEAT 21D WAS SMOKING AND THE IFE SYSTEM WAS TURNED OFF. MAINTENANCE REPLACE D THE VDU AND CHECKED THE SYSTEM TO BE SERVICEABLE. THIS COMPONENT WILL BE RETURNED TO THE MANUFACTURER AND A COMPLETE TEARDOWN REPORT WILL BE REQUESTED. THIS SDR WILL BE UPDATED ONCE THAT INFORMATION IS AVAILABLE.

CA050819002

BOEING

CFMINT

 

DISPLAY

FAILED

8/18/2005

73776N

CFM567B22

 

50401100003

SEAT 17F

(CAN) DURING AIRCRAFT BOARDING, THE CREW WAS ADVISED THAT THE VDU AT SEAT 17F WAS SMOKING, THE SYSTEM WAS TURNED OFF. MAINTENANCE REPLACED THE VDU AND CHECKED THE SYSTEM SERVICEABLE. THIS COMPONENT WILL BE RETURNED TO THE MFG AND A COMPLETE TEARDOWN REPORT WILL BE REQUESTED. THIS SDR WILL BE UPDATED ONCE THAT INFORMATION IS AVAILABLE.

CA050829005

BOEING

CFMINT

 

DISPLAY

INOPERATIVE

8/24/2005

73776N

CFM567B22

 

50401100003

SEAT 4E

(CAN) AC WAS IN CRUISE WHEN THE CREW WAS ADVISED THAT THE VDU AT SEAT 4E SMOKED. THE IFE SYSTEM WAS TURNED OFF. MAINTENANCE REPLACED THE VDU AND THE SYSTEM WAS TESTED SERVICEABLE. THIS COMPONENT WILL BE RETURNED TO THE MANUFACTURER AND A COMPLETE TEARDOWN REPORT WILL BE REQUESTED. THIS SDR WILL BE UPDATED ONCE THAT INFORMATION IS AVAILABLE.

CA050825002

BOEING

CFMINT

 

DISPLAY

FAILED

8/24/2005

7377CG

CFM567B22

 

50401100003

ENTERTAIN SYS

(CAN) ON AUGUST 24, 2005 A/C WAS IN CRUISE WHEN THE CREW WAS ADVISED THAT THE VDU AT SEAT 17C HAD QUIT WORKING AND THE PASSENGER SMELLED SMOKE. THE IFE SYSTEM WAS TURNED OFF AT THIS POINT. MAINTENANCE REPLACED THE VDU AND CHECKED THE SYSTEM SERVICEABLE. THIS COMPONENT WILL BE RETURNED TO THE MANUFACTURER AND A COMPLETE TEARDOWN REPORT WILL BE REQUESTED. THIS SDR WILL BE UPDATED ONCE THAT INFORMATION IS AVAILABLE.

CA050822004

BOEING

RROYCE

 

STRAP

CRACKED

8/20/2005

75728A

RB211535E437

 

AUL39151

ENGINE MOUNT

(CAN) DURING DAILY INSPECTION, FOUND LOW PRESSURE CASE UPPER ACCESSORY MOUNTING STRAP BROKEN.

CA050816001

BOEING

RROYCE

 

WINDSHIELD

CRACKED

8/13/2005

75728A

RB211535E437

 

1417480150

COCKPIT

(CAN) WHILE IN FLIGHT, THE FLIGHT CREW NOTICED ARCING INSIDE THE FIRST OFFICER WINDSHIELD WHICH RESULTED IN A SEVERELY CRACKED OUTER PANE.

2005FA0001279

BOEING

GE  

 

WATER HEATER

FAILED

8/24/2005

767*

CF680

 

ES1183206400DK

GALLEY

FA COMPLAINED ABOUT NO HOT WATER AT GALLEY SINK SHORTLY BEFORE LANDING. ONCE ON GROUND, MAINTENANCE EXPOSED WATER HEATER, GOT HEAVY BURNED SMELL. REMOVED FALSE PANEL COVERING WATER HEATER, NOTED THAT NO CB EITHER ON UNIT OR ON GALLEY CB PANEL HAD TRIPPED. DECIDED TO LOOK AT INSIDE OF INSTALLED UNIT TO SEE IF THERE WAS SOMETHING THAT COULD BE REPAIRED. LOOKED AS THOUGH THERE WAS A FIRE INSIDE OF UNIT. IT BURNED ITSELF OUT, NO EXTERNAL DAMAGE WAS DONE. PRIOR TO OPENING AREA WHERE HEATER IS INSTALLED, THERE WAS NO SMELL ANYWHERE IN GALLEY FROM THE FIRE, NO CB TRIPPED. UNIT WAS REMOVED FROM AC AND SENT TO THE MFG. NO REASON OR CAUSE HAS BEEN FOUND AT THIS TIME. (SW05200511531) (K)

CA050811001

BRAERO

RROYCE

 

TRANSDUCER

FAILED

8/9/2005

HS7482A

DART5342

 

 

STALL WARNING

(CAN) IN CRUISE, THE STICK SHAKER ACTIVATED WITH NO VISIBLE AIRFRAME ICING. THE AIRCRAFT RETURNED, WHERE MAINTENANCE REPLACED THE NR 2 STALL WARNING TRANSDUCER. THE AIRCRAFT RETURNED TO SERVICE WITH NO FURTHER PROBLEM.

CA050809002

BRAERO

RROYCE

 

ENGINE

FAILED

7/28/2005

HS7482A

DART5342

 

 

RIGHT

(CAN) AC WAS IN CRUISE, RT ENG WAS INDICATING NML, ENG SEEMED TO STUMBLE, COME BACK TO NML, THEN IMMEDIATELY FAILED. TEMP GAUGE FOR ENG RAPIDLY EXCEEDED 1000 DEGREES C, RPM DROPPED TOWARDS 0, TORQUE JUMPED THEN DROPPED TOWARDS 0. CAPT PULLED THROTTLE BACK, FEATHERED RT ENG IN ATTEMPT TO CNTRL TEMP. ENG FAILURE DRILL WAS COMPLETED, SOP AC LANDED WITH 1 ENG OPERATIONAL WITHOUT INCIDENT. REVIEW OF OP LIMITS OF MFG ENGINES, 1000 DEGREES C SURPASSES MAX TEMP ALLOWED. INFO STANDPOINT PROP WAS PULLED THROUGH WITH NO BINDING OR GRINDING PRESENT, PRESS FILTER WAS INSP, NO DEBRIS NOTED. BOTH COMPRESSOR INLET, JET PIPE EXIT INSPECTED NOTHING NOTED. ENG WAS CHANGED DUE TO TGT EXCEEDENCE, AC WAS RETURNED TO SERVICE.

2005FA0001291

CESSNA

CONT

 

CONTROL TUBE

CORRODED

9/2/2005

140  

IO240A

 

 

FLAP SYSTEM

THE IB RT FLAP AND SECTION OF THE FLAP CONTROL TUBE WERE EXAMINED. THE CONTROL TORQUE TUBE WELD CONTAINED SURFACE CORROSION AND A FATIGUE CRACK WAS NOTED.

CA050826002

CESSNA

CONT

SLICK

COIL

WEAK

8/15/2005

150J

O200A

4201

M3114C120783

LT MAGNETO

(CAN) RAN ROUGH SLIGHTLY MORE PROP THAN NORMAL. MAG DROP, WEAK SPARK, ABOUT .3333 OF NORMAL STRENGTH. OVERHAULED MAG WAS INSTALLED, 900 HOUR PREVIOUSLY.

2005FA0001201

CESSNA

CONT

FORD

ROTOR SHAFT

SHEARED

8/13/2005

150L

O200*

 

DOFF10300F

ALTERNATOR

ALTERNATOR SHAFT SHEARED AT BEARING LOCATION. DRIVE GEAR, BUSHINGS, RETAINER AND COUPLING ASSEMBLY ROLLED BETWEEN ENGINE ACCESSORY CASE AND DRIVE GEAR. THE SHAFT HAD BEEN PREVIOUSLY CRACKED OVER 50 PERCENT PRIOR TO FAILURE. (K)

2005FA0001230

CESSNA

LYC  

 

CARBURETOR

FAILED

8/18/2005

152  

O235L2C

 

75107922

ENGINE

WHILE IN THE PATTERN DOING LANDINGS. THE ENGINE QUIT WHEN THE POWER WAS REDUCED ON BASE LEG TO LAND. AN UNEVENTFUL LANDING WAS MADE, AND AFTER CLIMBING OUT OF AIRCRAFT, FUEL WAS COMING OUT OF THE COWLING. UPON FURTHER INVESTIGATION FOUND 1 OF THE FUEL BOWL FLOATS TO BE .7500 FULL OF FUEL AND THE OTHER WAS .2500 FULL. CAUSING THE FLOAT TO SINK AND CAUSING THE FUEL AIR MIXTURE TO BE TOO RICH AT REDUCED POWER SETTINGS. CAUSING THE ENGINE TO FLOOD OUT AND QUIT ON THE APPROACH TO LAND. (K)

CA050803008

CESSNA

LYC  

 

MOUNT

CRACKED

7/7/2005

172K

O320E2D

 

05510171

ENGINE

(CAN) 2 CRACKS FOUND AT LOWER CROSS TUBE SAME CRACKS FOUND ON PREVIOUS MOUNT. BOTH MOUNTS OVERHAULED, WELDING CRACKS LOCATED BESIDE WELD AREA SHOULD HAVE GUSSET PLATE WELDED AT THIS AREA TO RE-INFORCE.

CA050803004

CESSNA

LYC  

 

CARBURETOR

FAILED

7/29/2005

172M

O320E2D

 

MA45PA

ENGINE

(CAN) THIS OPERATOR HAS EXPERIENCED FOR THE SECOND TIME THE PROBLEM THAT THESE CARBURETORS HAVE WORKED LOOSE BETWEEN TOP AND BOTTOM HALVES, EVEN WITH ALL 4 SCREWS AND LOCKING TABS IN PLACE. THIS PROBLEM LEADS TO AIRCRAFT ENGINE RUNNING ROUGH, ALLOWING AIR TO ENTER BOND AND LET FUEL ESCAPE INTO ENGINE COMPARTMENT. IT APPEARS THAT DUE TO WEIGHT AND STRESS ASSOCIATED WITH CARBURETOR AIR BOX ATTACHED, THE CASTING OF THE LOWER HALF OF CARBURETOR CANNOT WITHSTAND THE WEIGHT AND THE THREADS ARE PULLED FREE THEREBY ALLOWING A SPLIT IN THE UNIT. VERY SERIOUS PROBLEM EXISTS AS A RESULT, ALLOWING RAW FUEL TO ENTER ENGINE COMPARTMENT AT CLOSE PROXIMITY TO EXHAUST.

CA050803001

CESSNA

LYC  

 

BOLT

BROKEN

8/2/2005

172N

O360A4A

 

NAS428H316

STABILIZER

(CAN) DURING THE WALK-AROUND THE PILOT NOTICED THE DOWN ELEVATOR STOP BOLT HEAD HANGING FROM THE LOCKWIRE. IT HAD BROKEN FROM THE SHAFT APPROXIMATELY 2MM FROM THE BOLT HEAD. THE BOLT WAS REPLACED NEW AND THE ELEVATOR TRAVELS AND FUNCTION WERE CHECKED.

05252001

CESSNA

LYC  

LYC  

SEAL

LEAKING

9/9/2005

172P

O320D2J

 

STD2217

ADAPTOR

FIRST 100 HOUR INSPECTION AFTER OVERHAUL BY MFG (ENGINE SMOH 98.5). FOUND OIL LEAKING FROM DRY VACUUM PUMP DRIVE. THE ENGINE VACUUM PUMP ADAPTOR DRIVE OIL SEAL WAS NOT SEATED FAR ENOUGH IN ADAPTOR HOUSING CAUSING LEAKAGE. REPLACED ADAPTOR DRIVE OIL SEAL AND REINSTALLED ADAPTOR AND PUMP WITH NEW GASKETS. OPERATIONAL AND LEAK CHECK SATISFACTORY. THIS IS THE SECOND OVERHAULED ENGINE WITH SAME PROBLEM.

2005FA0001302

CESSNA

LYC  

 

MOUNT

TORN

9/13/2005

172S

IO360A1A

 

J744442

COWLING

DURING THE COURSE OF A ROUTINE 100 HOUR INSPECTION, 3 OF THE RUBBER (LORD) COWLING MOUNTS WERE FOUND TORN. THIS HAS BEEN A COMMON OCCURRENCE SEEN WHILE MAINTAINING A FLEET OF THIS MODEL AC OPERATED BY A FLIGHT SCHOOL. IF NOT ADDRESSED THIS COULD LEAD TO A LOSS OF THE ENGINE COWLING IN FLIGHT. (K)

2005FA0001290

CESSNA

LYC  

 

OIL FILTER

LEAKING

9/15/2005

172S

IO360L2A

 

AA48111

ENGINE

INSPECTION OF AIRCRAFT FOLLOWING PILOTS COMPLAINT OF BURNING SMELL IN COCKPIT, AND OIL ON LOWER PART OF AIRCRAFT, REVEALED OIL LEAKING FROM THE BASE SEAM OF THE OIL FILTER. THE OIL LEVEL HAD GONE DOWN ONE HALF QUART IN THE ONE HOUR FLIGHT. THE LEAK WAS NOT FROM THE FILTERS BASE SEAL AND HAD BEEN PROPERLY TORQUED AND SAFETY WIRED IN PLACE. NO DAMAGE WAS VISIBLE ON THE FILTER.

2005FA0001199

CESSNA

LYC  

 

BULKHEAD

CRACKED

8/6/2005

172S

IO360L2A

 

 

PROP SPINNER

DURING ANNUAL/ 100 HOUR INSPECTION, FOUND SPINNER FWD BULKHEAD CRACKED AROUND 2 HOLES OF THE MOUNTING BOLTS. BOLTS PULLING EDGES OF BULKHEAD HOLES INTO CHAMFER OF THE PROP HOLES, CREATING STRESS AROUND THESE BULKHEAD HOLES LEADING TO CRACKS. (K)

CA050822002

CESSNA

LYC  

LAMAR

DRIVE ASSY

CRACKED

8/12/2005

172S

IO360L2A

 

 

STARTER

(CAN) PIC REPORTED A METAL GRINDING NOISE AT SECOND ATTEMPT TO START AIRCRAFT. FURTHER INVESTIGATION FOUND STARTER TOOTH MISSING AND TOOTH DRIVE CRACKED AND BROKEN IN SEVERAL SPOTS. RING GEAR FOUND MISSING TOOTH AND SEVERAL OTHER TEETH WE RE CHIPPED. ALL PARTS (STARTER AND RING GEAR) REPLACED WITH SERVICEABLE PARTS. AIRCRAFT RETURNED TO SERVICE.

2005FA0001237

CESSNA

CONT

 

CONNECTING ROD

BROKEN

8/30/2005

175  

GO300*

 

 

ENGINE

NR 3 CONNECTING ROD PENETRATED CASE. ENGINE TSO 848 HRS. LAST ENGINE O/H 06/10/1964 OR 41 YEARS AGO. MANUFACTURER RECOMMENDS 12 YEARS IAW SIL 98-9.

CA050824013

CESSNA

LYC  

 

CONNECTOR

CRACKED

8/9/2005

177  

O320E2D

 

69675

OIL SYSTEM

(CAN) OIL LEAK DISCOVERED. UPON LANDING, THE PILOT NOTICED THAT THERE WAS OIL IN THE WHEEL PAN. THE PILOT CARRIED OUT ONE MORE FLIGHT AND THE LEAK WAS REPAIRED AT A FACILITY. VERIFICATION REVEALED THAT THE CONNECTOR ASSEMBLY TO THE HSG COOLER INLET HOSE WAS CRACKED, AND ONCE IT WAS REMOVED, IT EMPTIED ALL ITS OIL. REPLACED THE CONNECTOR (P/N 69675) AND THE ANNULAR GASKET (P/N STD 294).

2005FA0001244

CESSNA

CONT

 

ATTACH FITTING

CORRODED

5/16/2005

310J

IO470U

 

08112763

WING TO BODY

DURING THE ANNUAL INSPECTION, THE WING FITTING WAS FOUND TO BE CORRODED SO SEVERE THAT IT WAS ALMOST .2500 OF THE WAY THRU THE FITTING. PICTURES ENCLOSED THAT SHOW DAMAGE. FITTING WAS LOCATED ON THE LT SIDE, AFT TOP FITTING. (K)

2005FA0001252

CESSNA

CONT

AIRESRCH

AIR FILTER

FAILED

6/21/2005

320E

TSIO520E

 

AM106735

TURBO CHARGER

ACCIDENT INVESTIGATION FOUND RIGHT TURBO CHARGER COMPRESSOR INGESTED PAPER AND JAMMED. IT WAS DETERMINED THAT THE PAPER WAS THE INSTRUCTIONS AND APPLICATION CHART FOR THE FILTER. A CHECK OF A NEW REPLACEMENT DONALDSON (FAA/PMA FOR CESSNA FILTERS) FILTER REVEALED THAT THE INSTRUCTIONS AND A STICKER WERE INSERTED INSIDE THE CANISTER TYPE FILTER. THE INSTRUCTIONS (FOLDED INTO A QUARTER SHEET) WERE LAYING (MOLDED) ON THE COURSE INSIDE SCREEN OF THE FILTER. IN-STOCK FILTERS SHOULD BE INSPECTED AND INSTRUCTIONS PLACE ON THE OUTSIDE OF THE FILTER.

2005FA0001259

CESSNA

CONT

 

ADAPTER

DAMAGED

9/1/2005

421C

GTSIO520*

 

643259

STARTER

METAL IN ENGINE. STARTER ADAPTER, CRANK GEAR HAD TEETH MISSING. SB WAS NEVER C/W. (K)

2005FA0001313

CESSNA

CONT

 

BELLCRANK

CRACKED

9/19/2005

421C

GTSIO520*

 

59420011

NLG STEERING

PILOT SAID PRESSURE REQUIRED TO MOVE RUDDER PEDALS WAS NOT NORMAL ON PREFLIGHT INSPECTION. NOSE GEAR STEERING BELLCRANK WAS CRACKED THROUGH AND BROKEN APART ON THE LT SIDE OF THE CENTER MOUNTING RADIUS. THE RT SIDE OF THIS RADIUS ALSO IS CRACKED.

2005FA0001314

CESSNA

CONT

 

BELLCRANK

CRACKED

9/19/2005

421C

GTSIO520*

 

59420011

NLG STEERING

PILOT SAID PRESSURE REQUIRED TO MOVE RUDDER PEDALS WAS NOT NORMAL ON PREFLIGHT INSPECTION. NOSE GEAR STEERING BELLCRANK WAS CRACKED THROUGH AND BROKEN APART ON THE LT SIDE OF THE CENTER MOUNTING RADIUS. THE RT SIDE OF THIS RADIUS ALSO IS CRACKED.

2005FAA09001

CESSNA

CONT

 

ALTERNATOR

DISLODGED

9/22/2005

421C

GTSIO520L

 

ALV9510R

ENGINE

THE ALTERNATOR, OVERHAULED UNIT, WAS IN PIECES WHEN THE AIRCRAFT LANDED. THE BACK HALF OF THE ALTERNATOR WAS OFF, THE STATOR WAS CHEWED UP. THE END BEARINGS WERE IN PLACE AND TURNED LIKE A NEW BEARING WITH GREASE IN THEM.

2005FA0001272

CESSNA

CONT

 

CRANKCASE

CRACKED

8/25/2005

421C

GTSIO520L

 

639468

ENGINE

OPERATOR COMPLAINT OF SMALL OIL LEAKS IN CRUISE FLIGHT. CLEANED ENGINE AND RAN, TO INSPECT FOR OIL LEAKS. AFTER EXTENSIVE VISUAL INSPECTION AND DYE PENETRANT INSPECTIONS (3) CRACKS IN THE CRANKCASE WERE DISCOVERED. (2) CRACKS WERE NOTED EXTENDING FROM TOP FORWARD CASE HALF BOLT HOLES. (1) CRACK WAS NOTED ON THE TOP LEFT CASE UNDER THE MAGNETO AREA. (K)

2005FA0001250

CESSNA

CONT

 

ENGINE

FAILED

8/5/2005

421C

GTSIO520L

 

GTSIO520L

RIGHT

DURING MAINTENANCE CHECK, RUNNING THE RT ENGINE AT 1200 RPM, ENGINE LOST OIL PRESSURE AND SHUT DOWN. THIS IS THE 2ND ENGINE THAT HAS FAILED WITHIN 30 HOURS OF INSTALLATION. BOTH ENGINE HAVE BEEN FROM SAME FACILITY.

2005FA0001249

CESSNA

CONT

 

ENGINE

SEIZED

1/17/2005

421C

GTSIO520L

 

GTSIO520L

RIGHT

OIL PRESSURE NEVER CAME UP AFTER PILOT STARTED ENGINE AND ENGINE SEIZED. TIME ON ENGINE: 03.3. ENGINE WAS REMOVED AND ANOTHER ENGINE WAS PROVIDED, UNDER WARRANTY TO TAKE ITS PLACE. PN: GTSIO520L/ SN: 292065R

2005FA0001268

CESSNA

 

CESSNA

STRUCTURE

CRACKED

10/20/2004

501  

 

 

 

SEAT BASE

UPPER CHAIR BASE ASSEMBLY CRACKED AT CHAIR BACK ATTACH POINTS. STRESS ON CHAIR BACK AND METAL FATIGUE PROBABLE CAUSE. CHAIR WAS REPAIRED IAW STRUCTURAL SEAT REPAIR. (K)

CA050812001

CESSNA

PWA  

 

STOP

MISSING

8/12/2005

550  

JT15D4

 

50110502

SEAT 

(CAN) COMPANY CAMPAIGN NOTICE 851-25-26-029 WAS CREATED TO INSPECT FOR PROPPER INSTALLATION OF PASSENGER SEAT STOPS. DURING INSPECTION IT WAS FOUND THAT 4 STOPS WERE MISSING ON THE LT BACK TO BACK SEAT INSTALLATION. PARTS ARE ORDERED AND WILL BE INSTALLED PRIOR TO NEXT FLIGHT.

CA050812002

CESSNA

PWA  

 

STOP

MISSING

8/11/2005

550  

JT15D4

 

50110502

COCKPIT SEATS

(CAN) COMPANY CAMPAIGN NOTICE 851-25-26-029 WAS CREATED TO INSPECT FOR PROPPER INSTALLATION OF PASSENGER SEAT STOPS. DURING INSPECTION IT WAS FOUND THAT 4 STOPS WERE MISSING ON THE LT BACK TO BACK SEAT INSTALLATION. PARTS ARE ORDERED AND WILL BE INSTALLED PRIOR TO NEXT FLIGHT.

CA050824018

CESSNA

PWA  

 

LINE

CHAFED

8/23/2005

560XL

PW545A

 

661707720

HYDRAULIC SYS

(CAN) DURING PHASE 5 INSP, 2 HYDRAULIC LINES FOUND CHAFING ON STRUCTURE. P/N 6617077-19 AND 20. REF. AC MFG PROVIDED ENG MFG WITH DRAWING TO INSTALL MISSING LINE SUPPORT HARDWARE TO PREVENT CHAFING.

CA050815002

CESSNA

CONT

 

LINE

CORRODED

7/14/2005

A185F

IO520D

 

0500106354

FUEL SYSTEM

(CAN) DURING TROUBLESHOOTING, FOUND FUEL CROSS-FEED LINE ROUTED THROUGH RT DOOR POST WEEPING FUEL. PORTION OF LINE REMOVED AND UPON FURTHER EXAMINATION A PIN-HOLE CAUSED BY CORROSION WAS FOUND UNDER PLASTIC ANTI-CHAFE MATERIAL. SUSPECT CONDENSATION OVER MANY YEARS CAUSED CORROSION TO FORM UNDER PLASTIC SHEATH. REFERENCE TO FIGURE 99 OF AIRCRAFT IPC.

2005FA0001298

CESSNA

CONT

 

ALTERNATOR

FAILED

12/9/2004

T210M

TSIO520*

 

DOF10300B

ENGINE

OVERHAULED ALTERNATOR FAILED IN FLIGHT AFTER 351 HOURS IN SERVICE.

2005FA0001242

CESSNA

 

CESSNA

PIN  

BACKED OUT

8/29/2005

T210N

 

 

S26376Z11

ZONE 300

THE PIN THAT HOLDS THE DRIVE GEAR ONTO THE ACTUATOR DRUM HAD FALLEN OUT WHEN THE AIRCRAFT WAS TRIMMED NOSE UP. THE PILOT HAD TO PUSH ON THE YOKE WITH GREAT FORCE TO PITCH THE AIRCRAFT DOWN. AFTER EXAMINING THE ACTUATOR I NOTICED THAT THE HOLE FOR THE PIN WAS ELONGATED AND WOULD NOT HOLD A NEW PIN. I WOULD RECOMMEND SOME SORT OF CLAMP BE INSTALLED TO INSURE THE PIN COULD NOT BACK OUT.

2005FA0001238

CESSNA

CONT

CESSNA

PIN  

BACKED OUT

8/29/2005

T210N

TSIO520*

 

S26376Z11

ACTUATOR

THE PIN THAT HOLDS THE DRIVE GEAR ONTO THE ACTUATOR DRUM HAD FALLEN OUT WHEN THE AIRCRAFT WAS TRIMMED NOSE UP. THE PILOT HAD TO PUSH ON THE YOKE WITH GREAT FORCE TO PITCH THE AIRCRAFT DOWN. AFTER EXAMINING THE ACTUATOR, NOTICED THAT THE HOLE FOR THE PIN WAS ELONGATED AND WOULD NOT HOLD A NEW PIN. RECOMMEND SOME SORT OF CLAMP BE INSTALLED TO INSURE THE PIN COULD NOT BACK OUT.

2005FA0001251

CESSNA

CONT

CESSNA

CLAMP

SEPARATED

3/14/2005

T337G

IO360*

 

S19211

TURBOCHARGER

EXHAUST PIPE TO TURBOCHARGER CLAMP FOR FRONT ENGINE CRACKED AT SPOT-WELD AND SEPARATED ON TAKEOFF. WHEN THIS HAPPENED, THE EXHAUST PIPE DEPARTED THE AIRCRAFT AND THE EXHAUST SCORCHED THE ENGINE COWLING AND FIREWALL. (K)

MAFALT4

CESSNA

CONT

ELECTROSYS

ROTOR

FAILED

9/2/2005

TU206G

TSIO520M

 

C6FF10335B

ALTERNATOR

ELECTROSYSTEM WOES CONTINUE, WITH ANOTHER ROTOR GOING BAD. DETAILS: M/N DOFF10300BR S/N B110413 WITH A TS0 :1095.1 ON THE ALTERNATOR. THE ROTOR WAS CHANGED 3 DIFFERENT TIMES ON THIS ALTERNATOR AND IT RAN ON FOUR DIFFERENT A/C IN IT'S LIFE HERE. THIS LAST ROTOR RAN FOR 188.1 HRS. TIS, AND PREVIOUS ROTORS ONLY RAN 18.9HRS AND 1 HR. MORE IN-DEPTH INSPECTION OF THE ALTERNATOR FOR A REOCURRING FAULT HAS TURN UP NOTHING, AS TO A CAUSE FOR ROTORS CONTINUING TO FAIL. SINCE A RECENT RASH OF ROTOR FAILURES ON OTHER ALTERNATORS, POSSIBLY AN ISSUE WITH THE MANUFACTURE, ELECTORSYSTEMS AND THE QUALITY OF ROTORS.

CA050818004

CESSNA

CONT

 

BOLT

BROKEN

8/18/2005

U206G

IO520F

 

NAS14740

MLG 

(CAN) PILOT REPORT: NO BRAKE ON RT SIDE OF AIRCRAFT. BRAKE PEDDLE WAS SOLID, NO TRAVEL. INSPECTION REVEALED THAT THE OB MLG CLAMP AFT BOLT HAD SNAPPED ALLOWING THE GEAR TO COME LOOSE. THE MAIN LANDING GEAR HAD PINCH OFF THE SOLID ALUMINUM BRAKE LINE.

0509137A

CIRRUS

 

 

EXHAUST RISER

FAILED

9/6/2005

SR22

 

 

15070001

NR 5 

NR 5 EXHAUST RISER HAD SEPARATED FROM ENGINE JUST BELOW THE FLANGE WELD. THE OWNER STATED THIS WAS THE SECOND TIME THIS HAS HAPPENED IN 40 HOURS. REPLACED ALL 3 RISERS AND COLLECTOR.

M1555

CIRRUS

CONT

 

BRACKET

SPLIT

9/2/2005

SR22

IO550*

 

 

OIL FILTER

DURING SCHEDULED ENGINE OIL CHANGE, FOUND BRACKET INDUCTION AIR FILTER SPLIT AT MANUFACTURED SEAM. SUSPECT ADHESIVE USED AT MANUFACTURE OF THE FOAM TYPE FILTER IS INADEQUATE FOR THE TASK.

2005FA0001232

CIRRUS

CONT

 

LINE

CHAFED

8/19/2005

SR22

IO550*

 

11443004

FUEL SYS

MAIN FUEL SUPPLY LINE FROM FUEL SELECTOR TO FIREWALL HAD HOLE CHAFED IN IT. THE WIRE BUNDLE TO THE CB PANEL WAS CHAFING LINE. (K)

CA050803009

CIRRUS

CONT

 

EXHAUST HEADER

SEPARATED

8/3/2005

SR22

IO550N

 

15070001

ENGINE

(CAN) PILOT HEARD UNUSUAL EXHAUST NOISE FROM ENGINE.ON INSPECTION, FOUND NR 5 CYLINDER EXHAUST HEADER HAD SEPARATED .1875 INCH FROM THE FLANGE JUST BELOW THE WELD.

CA050815003

CNDAIR

GE  

 

WIRE

DAMAGED

8/10/2005

CL6002B19

CF343A1

 

601R577921

ENGINE

(CAN) INITIAL INVESTIGATION OF RT FIRE INDICATION LEADS US TO BELIEVE THAT A CHAFED IDG HARNESS ARCED AGAINST MAIN FUEL CONTROL. THIS ACTION CAUSED MAIN FUEL CONTROL TO LEAK WHICH LEAD TO THE SMALL CONTAINED OVERHEATING EVENT. THIS CAUSED FIRE SYSTEM TO ALERT THE CREW. IAW QRH, FLIGHT CREW ACTUATED THE (ENGINE FIRE PUSH) SWITCH AND SHUTDOWN THE ENGINE. INITIAL REPORTS SHOW THAT AFTER THE (ENGINE FIRE PUSH) SWITCH WAS PRESSED THE FIRE MESSAGE WENT OUT. NO FIRE BOTTLES WHERE DISCHARGED AND THE AIRCRAFT LANDED SAFELY. POST INCIDENT INSPECTIONS REVEALED THAT THE CLAMP THAT RESTRAINED THE IDG HARNESS AT THE TOP OF THE SERVICE PANEL WAS LOOSE AND ALLOWED THE IDG HARNESS TO MOVE. ENGINE WAS REMOVED AND REPLACED.

CA050817007

CNDAIR

GE  

 

BLOCK

WORN

7/19/2005

CL6002B19

CF343B1

 

TA3050052403

FAIRLEAD

(CAN) DURING AN INSPECTION AME FOUND DAMAGE ON NR 2 HYDRAULIC SUCTION LINE UPSTREAM OF RESERVOIR DAMAGE CAUSED BY WORN FAIRLEAD BLOCK ALLOWING HYD SUCTION LINE TO CHAFE ON CASE DRAIN LINE.

CA050817008

CNDAIR

GE  

 

BLOCK

WORN

7/19/2005

CL6002B19

CF343B1

 

601R7528651

FAIRLEAD

(CAN) DURING AN INSPECTION AME FOUND DAMAGE ON NR 2 HYDRAULIC CASE DRAINLINE UPSTREAM OF RESERVOIR. DAMAGE CAUSED BY WORN FAIRLEAD BLOCK ALLOWING HYDCASE DRAIN LINE AND SUCTION LINE TO CHAFE.

CA050825004

CNDAIR

GE  

 

WINDOW

CRACKED

8/19/2005

CL6002B19

CF343B1

 

NP1393226

COCKPIT

(CAN) RT SIDE WINDOW CRACKED IN FLIGHT. A/C LANDED. A/C FERRIED FOR WINDOW REPLACMENT. WINDOW REMOVED AND INSTALLED = P/N NP139322-12, S/N 05200H6110.

CA050826001

CNDAIR

GE  

 

HEAT EXCHANGER

LEAKING

8/19/2005

CL6012A12

CF34*

 

702101600641

FUEL/OIL

(CAN) DURING TROUBLESHOOTING TO FIND CAUSE FOR LOW OIL PRESSURE AT HIGH POWER IT WAS DISCOVERED THAT THE OIL HAD BECOME CONTAMINATED WITH FUEL AND SUBSEQUENTLY LOWERED IN VISCOSITY CAUSING LOW OIL PRESSURE READINGS. THE OIL TO FUEL HEAT EXCHANGER, FUEL HEATER/OIL COOLER HAD FAILED INTERNALLY AND WAS ALLOWING HIGHER PRESSURE FUEL TO CONTAMINATE THE ENGINE OIL SYSTEM. THE UNIT WAS REPLACED, ENGINE OIL CHANGED AND THE AIRCRAFT RETURNED TO SERVICE.

2005FA0001273

CNDAIR

 

 

WIRE

SHORTED

10/15/2004

CL6013A

 

 

 

VERTICAL STAB

WHILE TROUBLESHOOTING INTERMITTENT UPPER BEACON CIRCUIT BREAKER FAULT, DISCOVERED LT ELEVATOR CONTROL CABLE HAD TORN THROUGH WIRING CONDUIT IN VERTICAL STABILIZER. THE CABLE WORE THROUGH THE CONDUIT AND SHORTED OUT THE WIRING FOR THE UPPER BEACON. REPAIRED WIRING CONDUIT, REPLACED WIRING AND REPLACED CONTROL CABLE IAW MFG INSTRUCTIONS. REPAIR OF CONDUIT ALLOWED SUFFICIENT CLEARANCE BETWEEN CABLE AND CONDUIT. UNCLEAR IF CONDUIT WAS INSTALLED AT FACTORY OR AT TIME OF COMPLETION. SUGGEST INSPECTION OF THIS AREA ON OTHER SIMILAR AIRCRAFT. DEFECT DIFFICULT TO NOTICE DUE TO ACCESSIBILITY OF AREA IN TAIL. (K)

CA050822006

CVAC

ALLSN

 

DOOR

OPEN

8/16/2005

340CVAC

501D13D

 

 

MAIN PAX

(CAN) ON DEPARTURE, ON TAKEOFF ROLL JUST AT THE POINT OF ROTATION THE MAIN ENTRANCE DOOR OPENED. THE CREW IMMEDIATELY RETURNED TO THE AIRPORT AND EXECUTED AN UNEVENTFUL LANDING. THE MAINTENANCE CREW INSPECTED THE DOOR AND SURROUNDING STRUCTURE, AND CHECKED THE RIGGING OF THE DOOR LOCKING SYSTEM. NO DEFECTS WERE FOUND AND THE AIRCRAFT WAS RETURNED TO SERVICE.

CA050824020

CVAC

ALLSN

 

WIRE

SHORTED

8/21/2005

340CVAC

501D13H

 

356080765

NR 2 FIRE DETECT

(CAN) DURING CLIMBOUT, NR 2 ENGINE ZONE 1 FIRE LIGHT ILLUMINATED AND BELL SOUNDED. THE ENGINE WAS E-HANDLED, NO OTHER INDICATION OF FIRE WAS EVIDENT. THE AIRCRAFT LANDED SAFELY. DURING INVESTIGATION BY MAINTENANCE STAFF THE FIRE ELEMENT P/N 35608-0-765 WAS INDICATING A SHORT. THE ELEMENT WAS REPLACED AND THE SYSTEM TESTED SERVICEABLE. THE AIRCRAFT WAS RETURNED TO SERVICE.

CA050823007

CVAC

ALLSN

 

HOOK

FAILED

8/19/2005

440  

501D13D

 

 

SERVICE DOOR

(CAN) WITH AN AIRCRAFT MECHANIC AND 2 FLIGHT ATTENDANTS ON BOARD, THE REAR SERVICE DOOR OPEN WARNING LIGHT CAME ON AT 14,000 FEET. AIRCRAFT DEPRESSURIZE AND RETURN TO DEPARTURE. INVESTIGATION REVEALED THAT LOWER REAR HOOK WAS NOT GOING IN PLACE PROPERLY, DOOR WAS RE-RIGGED IAW MM FIG. 3.2.103. AIRCRAFT RETURN TO SERVICE.

CA050823005

CVAC

ALLSN

 

BEARING

FAILED

8/19/2005

440  

501D13D

 

671657

ENGINE

(CAN) WITH AN AIRCRAFT MECHANIC AND 2 FLIGHT ATTENDANTS ON BOARD, NR 1 ENGINE FLAMED OUT IN DESCENT, AIRCRAFT LANDED SAFELY AT AIRPORT. AFTER EVALUATION, THE POWER SECTION ACCESSORIES GEARBOX WAS FOUND AT FAULT, TOWER SHAFT BEARING (RR. IPC 72-60-00 FIG. 3 ITEM 2 P/N 671657) HAD FAILED. GEARBOX WAS REPLACED AND AIRCRAFT RETURN TO SERVICE.

CA050728005

DHAV

PWA  

EDOXXXXXXXXX

MECHANISM

BROKEN

7/27/2005

DHC2*

R985AN14B

 

C2UF2291

WIRE PULL

(CAN) THE AIRCRAFT LANDED IN ROUGH WATER THE UPPER RT WIRE PULL P/N C2UF2291 FAILED.

CA050728006

DHAV

PWA  

EDOXXXXXXXXX

FITTING

CRACKED

7/22/2005

DHC2*

R985AN14B

584580

585926R

FLOAT

(CAN) INTERGRANULAR CORROSION AT FORWARD FLOAT STRUT FITTING P/N 585926R FOUND DURING A 400 HOUR INSPECTION.

CA050803003

DHAV

PWA  

 

SEGMENT

CRACKED

7/28/2005

DHC2*

R985AN14B

 

C2EE247AND

EXHAUST ASSY

(CAN) THE PILOT REPORTED AN INTERMITTENT (POPPING) SOUND DURING ALL PHASES OF OPERATION. MAINTENANCE INVESTIGATION REVEALED A CRACK AND BLOWN EXHAUST GASKET ON NR 3 CYLINDER EXHAUST SEGMENT. THE CRACK EXTENDED AROUND MOST OF THE FLANGE, AND WAS CREEPING UP THE STUB APPROXIMATELY 1 INCH. THE SEGMENT WAS WELD REPAIRED AND REINSTALLED.

CA050803007

DHAV

PWA  

 

PUSHROD

BROKEN

7/4/2005

DHC3

R1340*

 

 

ENGINE

(CAN) NR 2 CYL EXHAUST ALUMINUM PUSH ROD BROKEN NEAR THE TOP FITTING.

CA050711007

DHAV

PWA  

 

STRUT

DAMAGED

7/8/2005

DHC6200

PT6A20

 

C6UF101527

MLG 

(CAN) DURING WALKAROUND, THE FLIGHT CREW OBSERVED A RIVET HEAD MISSING FROM THE OUTSIDE OF THE LOWER LUG OF THE LT FORWARD FLOAT STRUT. THE AIRCRAFT WAS FERRIED TO MAINTENANCE WHERE THE STRUT WAS REMOVED AND INSPECTED. THE RIVET STEM SHOWED SIGNS OF INTERNAL CORROSION. ALL OTHER RIVETS ON THE STRUT WERE INSPECTED SERVICEABLE. THE ONE RIVET WAS REPLACED AND THE AREA REPROTECTED. THE STRUTS ARE NOT TRACKED SO NO TIME IN SERVICE IS AVAILABLE.

CA050815004

DHAV

 

 

ISOLATION VALVE

LEAKING

8/11/2005

DHC8*

 

 

FSCM79318

DE ICE SYSTEM

(CAN) WHILE COMPLETING THE DE-ICE PRESSURE REGULATOR FUNCTION CHECK THE WING DE-ICE ISOLATION VALVE WAS FOUND TO BE LEAKING (NOT CLOSING COMPLETELY) ALLOWING AIR PRESSURE TO BOTH WINGS. TWO OTHER ISOLATION VALVES WERE FUNCTION CHECKED AND WERE ALSO FOUND NOT CLOSING COMPLETELY.

CA050822005

DHAV

PWA  

HAMSTD

BLADE

CORRODED

8/22/2005

DHC8*

PW121

14SF7

SFA13M1R0AD

PROPELLER

(CAN) AIRCRAFT, BLADE RECEIVED FOR MAJOR INSP. DURING INSP OF THE BLADE SHANK IAW CMM, WAS FOUND WITH CORROSION PITTING AND ETCHING OF THE ALUMINIUM SURFACE. DURING INSP OF THE TAPERBORE IAW CMM, CORROSION PITTING WAS FOUND. ZONE 5 IS NOT ALLOWED ANY CORROSION DAMAGE, THERE IS PITTING VISIBLE. THE BLADE MUST BE REMOVED FROM SERVICE IAW CMM, NO CORROSION PITTING ALLOWED, THE BLADE IS MARKED TO SHOW THAT IS IN COMPLIANCE WITH FAA AD 96-08-02. CORROSION IN THE TAPER BORE WAS PREVIOUSLY ADDRESSED BY CURRENT FAA AD 96-08-02.

CA050803002

DHAV

PWA  

 

BOLT

DAMAGED

8/1/2005

DHC8*

PW123

 

54C546349

SEQUENCE VALVE

(CAN) DURING A LANDING, AN AIRCRAFT EXPERIENCED LOSS OF MOST OF NR 2 HYDRAULIC SYSTEM CONTENTS. THE DEFECT WAS TRACED TO FAILURE OF LT DOOR SEQUENCING UNIT PART NR 54C54634-9, WHICH HAD SUFFERED SEVERE HYDRAULIC FORCED DAMAGE THAT 2 OF THE BOLTS SHEARED WITH THE FORCE. THIS UNIT WAS REPLACED AND THE HYDRAULIC SYSTEM SERVICED, FUNCTION FLIGHT CARRIED OUT SYSTEM SATISFACTORY AND AIRCRAFT RELEASED TO SERVICE.

CA050825003

DHAV

PWA  

 

ACTUATOR

CRACKED

8/21/2005

DHC8101

PW120A

 

A44700009

RT IB SPOILER

(CAN) AT LINE UP FOR TAKEOFF CREW OBSERVED NR 1 HYD SYSTEM AND IB ROLL SPOILER CAUTION LIGHTS ILLUMINATED. AIRCRAFT RETURN TO BLOCKS. INVESTIGATION REVEALED SIGNIFICANT HYDRAULIC LEAKAGE FROM THE AREA OF THE RT IB SPOILER ACTUATOR. CLOSER INSPECTION OF THE SPOILER ACTUATOR REVEALED A METAL FATIGUE FAILURE OF THE SPOILER ACTUATOR BODY ALLOWING LIBERATION OF THE FLUID CONTENT OF THE NR 1 HYDRAULIC SYSTEM. THE FAILED SPOILER ACTUATOR WAS REPLACED AND FOLLOWING APPROPRIATE MAINTENANCE CHECKS THE AIRCRAFT WAS RETURNED TO SERVICE WITHOUT FURTHER INCIDENT.

CA050823002

DHAV

PWA  

 

ALTIMETER

SEPARATED

8/22/2005

DHC8102

PW120A

 

 

COCKPIT

(CAN) WHEN ANTENNA WAS REMOVED FOR INSPECTION AND CLEANING, IT CAME APART IN 2 PIECES. CORROSION WAS FOUND INTERNALLY BETWEEN BASE PLATE AND COPPER ANTENNA PLATE. SUSPECTED CAUSE FOR INTERMITTENT GPWS/RAD ALT SNAGS FOR THE PAST MONTH. ( REFERENCE A/C JOURNEY LOG PAGES : 435367,435362 AND 431947 ) NOTE: THIS PART IS TRACKED AS AN EXPANDABLE PART IN OUR SYSTEM, THUS WE ARE UNABLE TO DETERMINE THE EXACT TSN AND CYCLE ON UNIT.

CA050817005

DHAV

PWA  

 

CDU  

FAILED

8/15/2005

DHC8102

PW120A

 

201741211

FMS 

(CAN) 1 FMS CDU, DURING CRUISE AT FL210, FMS SCREEN NR 1 FAILED WITH HEAVY SMOKE FROM UNIT, SMOKE CONTINUED FOR ABOUT 1 MIN OR SO, THEN DISSIPATED. (P6 NLG STEER CONT) BREAKER WAS ONLY BREAKER THAT WAS POPPED. RECERTIFICATION DETAILS: 15 AUG 05, NR 1 FMS CDU REPLACED AND TESTED SERVICEABLE IAW AMM. P/N 2017-41-211, S/N OFF: 341, S/N ON: 565. L/S 464094: C/B P6 RESET STEERING BY TE TEST COMPLETED, NO FAULT FOUND, TEARDOWN REPORT IS NOT AVAILABLE, SO DETAILS ABOUT THE SPECIFIC PART CAUSING DIFFICULTY IS NOT KNOW AT THIS TIME. UPDATE SDR WHEN INFORMATION IS RECEIVED.

CA050819001

DHAV

PWA  

 

CHECK VALVE

LEAKING

8/19/2005

DHC8301

PW123

 

DSC1896

NR 2 HYD SYSTEM

(CAN) AN OPERATOR EXPERIENCED A LOSS OF HYDRAULIC SYSTEM NR 2, IN FLIGHT, DUE TO A FRACTURED CHECK VALVE. A VISUAL INSPECTION OF THE CHECK VALVE REVEALED A CRACK AROUND THE CIRCUMFERENCE OF THE VALVE BODY. THE CHECK VALVE IS BEING RETURNED TO MFG FOR INVESTIGATION.

CA050803005

DHAV

PWA  

 

LINE

LEAKING

7/20/2005

DHC8311

PW123

 

82950010271

HYD SYSTEM

(CAN) CAPTAIN REPORTED A LOSS OF FLUID FROM NR 1 HYDRAULICS. EVERYTHING SEEMED TO OPERATE NORMALLY, BUT CREW ELECTED TO DO THE FLAPLESS LANDING IN CASE OF A GO AROUND. NR 1 HYDRAULIC SYSTEM DRAINED DOWN TO 1 QUART INFLIGHT. FOUND IB ROLL SPOILER PRESSURE CHD LINE WITH A PIN HOLE AT 90 DEGREE BEND ABOUT 3 INCHES FORM ACTUATOR PORT.

CA050823001

EMB  

PWA  

 

SUPPORT

CRACKED

8/22/2005

EMB110P1

PT6A34

 

1105031412

TE FLAPS

(CAN) DURING A ROUTINE INSPECTION, MAINTENANCE FOUND A CRACK IN THE RT FLAP ASYMMETRY TELEFLEX CABLE SUPPORT. THIS SUPPORT IS LOCATED ON THE RT FLAP IB SUPPORT AND IS ATTACHING POINT FOR ASYMMETRY DETECTOR TELEFLEX ROD END. FURTHER INVESTIGATION, A SECOND CRACK WAS ALSO FOUND ON SAME PART. BOTH CRACKS WERE ADJACENT TO SUPPORT ATTACH BOLT HOLES. FIRST CRACK PROPAGATED FROM UPPER PORTION OF SUPPORT AND MEASURED APPROX 1.25 INCHES IN LENGTH. SECOND CRACK PROPAGATED FROM LOWER PORTION OF SUPPORT, MEASURED APPROX .25 INCHES IN LENGTH. THE SUPPORT WAS REPLACED AND THE AIRCRAFT RETURNED TO SERVICE.

CA050817009

GRUMAN

WRIGHT

 

WIRE

SHORTED

8/12/2005

TS2ACALFORST

982C9HE2

 

702054

FIRE DETECTOR

(CAN) WHILE AIRCRAFT WAS IN CRUISE, THE FIRE INDICATOR LIGHT FOR THE LT ENGINE ILLUMINATED. THE PILOT RELEASED THE RETARDANT LOAD, THROTTLED THE ENGINE BACK AND SHUTDOWN THE ENGINE. WHEN THE ENGINE WAS SHUTDOWN THE WARNING LIGHT EXTINGUISHED. THE AIRCRAFT RETURNED TO BASE. DURING INVESTIGATION BY MAINTENANCE THE FIRE DETECTOR WIRE WAS INDICATING A PARTIAL SHORT. THE FIRE DETECTOR WIRE WAS REPLACED AND THE AIRCRAFT WAS RETURNED TO SERVICE.

CA050817010

GRUMAN

WRIGHT

BENDIX

SEAL

BLOWN

8/12/2005

TS2ACALFORST

982C9HE2

147515

148144

BRAKE SEAL

(CAN) AFTER TAKEOFF THE PILOT NOTICED FLUID LEAKING FROM THE LT BRAKE. UPON LANDING THE PILOT NOTICED THERE WAS NO FEED BACK FROM THE LT BRAKE PEDAL. THE AIRCRAFT LANDED UNEVENTFULLY. DURING INVESTIGATION MAINTENANCE NOTED THAT THE BRAKE SEAL HAD BLOWN. THE BRAKE ASSY WAS REPLACED WITH A SERVICEABLE UNIT AND THE AIRCRAFT WAS RETURNED TO SERVICE.

2005FA0001202

GULSTM

 

 

STARTER

FAILED

8/17/2005

680E

 

 

75622CG

ENGINE

ON START UP FOR SECOND FLIGHT OF THE DAY, AC STARTER WOULD NOT ENGAGE AND TURN ENGINE. SEVERAL ATTEMPS WERE MADE TO START THE ENGINE. STARTER WOULD TURN BUT WOULD NOT ENGAGE AND TURN OVER ENGINE. THIS STARTER WAS INSTALLED ON THIS AIRCRAFT ON THE SAME ENGINE AND REMOVED FOR THE SAME REASON IN 10/17/01. (K)

2005FA0001229

GULSTM

GARRTT

 

CONNECTOR

WORN

8/3/2005

690C

TPE3315

 

MS25182-2

BATTERIES

PILOT REPORTED INABILITY OF "SERIES" START WITH A/C. UPON INSPECTION FOUND + PIN OF RH BATTERY BROKEN OFF IN BATTERY CONNECTOR. INSPECTED LH BATTERY FOUND + PIN WITH PARTIAL BURN INDICATION. REMOVED TOPS OF BOTH BATTERIES AND NOTED INDICATION OF HIGH HEAT ABOVE CONNECTOR TERMINAL AREA. CONTACTED FSI MAINT TRAINING INSTRUCTOR, INDICATED SIMILAR CONDITION FOUND RECENTLY ON SAME TYPE PLANE AT EAGLE AVIATION. BATTERY CONNECTOR FOUND TO HAVE LOST TENSION ON CONNECTOR PINS. PREVIOUSLY DISCUSSED SIMILAR PROBLEM WITH GILL MANUFACTURING. TECHNICIAN SAID WITH LOOSE PINS IN CONNECTOR, CREATES HIGH RESISTANCE, WITH HIGH TEMP ON CONNECTOR AREA AND WILL CAUSE AREA TO CRACK DUE TO HEAT. REPLACED BOTH G-6381E BATTERIES AND REBLING CONNECTORS, CHECKED GEN OUTPUT AT BUSS, A/C RETURNED TO SERVICE.

AMCR200500008

GULSTM

RROYCE

 

SWITCH

SEPARATED

9/15/2005

GIV  

TAY6118

 

6014303

AUTOPILOT

DURING CLIMB, CREW COULD NOT ENGAGE AUTOPILOT. DURING HAND FLYING, CREW GOT SEVERAL UNCOMMANDED GO-AROUND COMMANDS IN WHICH COMMAND BARS WOULD POP-UP AND THROTTLES WOULD ADVANCE TO FULL POWER. MX FOUND THE BODY OF GO-AROUND SWITCH HAD SEPARATED WHICH CAUSED SWITCH TO RECESS A BIT INTO THE YOKE. BECAUSE SWITCH POSTS DID NOT HAVE HEAT SHRINK ON THEM, THEY WERE SHORTING OUT CAUSING THE UNCOMMANDED GO-AROUND SCENERIO. MX ENSURED SHRINK TUBE WAS INSTALLED ON NEW SWITCH.

20050908

HELIO

 

 

TUBE

CRACKED

9/9/2005

H295

 

 

B4015

ZONE 200

CARRY-THRU VERTICAL TUBE CRACKED ON CARRY-THRU ASSEMBLY. THIS CARRY-THRU IS MODIFIED BY STC SA1590CE. TIME IN SERVICE IS UNKNOWN. ALSO NOTED IS THAT THE VERTICAL TUBE WALL THICKNESS WAS .065 INCH RATHER THAN .120 INCH. THE HEAVIER WALL THICKNESS OF .120 IS CALLED OUT ON THE DRAWING AND IT IS SURMISED THAT SOME EARLY SERIAL NUMBER CARRY-THRU'S HAD THE LIGHTER WALL TUBE INSTALLED. THIS AIRPLANE WAS TOSSED IN A TORNADO AND SUSTAINED DAMAGE TO THE RT MAIN GEAR ATTACHMENT, PROPELLER, AND RT WING. INSPECTED THE CARRY-THRU FOR HIDDEN DAMAGE. PLEASE NOTE, HAVE FOUND OTHER CARRY-THRU'S WITH CRACKED VERTICAL TUBES RESULTING FROM FATIGUE.

CA050825001

HUGHES

LYC  

 

RING

FAILED

8/17/2005

269C

HIO360D1A

 

LW19047

NR 3 CYLINDER

(CAN) HEAVY OIL CONSUMPTION CYLINDER NR 3. OIL RING NOT PERFORMING ITS WORK. REMOVED AND SENT FOR REPAIR. REINSTALLED CYLINDER.

2005FA0001285

HUGHES

LYC  

 

HINGE

FAILED

8/27/2005

269C1

HIO360*

 

269A475511

PAX DOOR

THE DOOR PIN PORTION OF THE HINGE, WHICH IS RESPONSIBLE RETAINING THE DOOR, FAILED. THIS LEAVES THE DOOR CONNECTED AT ONLY ONE POINT AND AN IN-FLIGHT FAILURE COULD POTENTIALLY ALLOW THE DOOR SEPARATE FROM THE AIRCRAFT. (K)

2005FA0001286

HUGHES

LYC  

 

HINGE

BROKEN

8/30/2005

269C1

HIO360*

 

269A475511

PAX DOOR

THE DOOR PIN PORTION OF THE HINGE, WHICH IS RESPONSIBLE RETAINING THE DOOR, BROKE IN FLIGHT AND THE DOOR WAS UNSECURED AT THE LOWER CONNECTING POINT. THE FLIGHT CREW LANDED, THE DOOR WAS SECURED TEMPORARILY AND THE AIRCRAFT RETURNED TO THE MAINTENANCE FACILITY. (K)

2005FA0001266

ISRAEL

GARRTT

 

SEAT

BROKEN

8/25/2005

ASTRASPX

TFE731*

 

5110023000

BACKREST FRAME

DURING REUPHOLSTERY OF PILOT SEAT, FOUND BACKREST FRAME BROKEN. CONTACTED MFG AND WAS GIVEN REPAIR TO ADD WELDED DOUBLERS. (CE09200505050) (K)

2005FA0001203

ISRAEL

GARRTT

 

ATTACH BRACKET

LEAKING

7/5/2005

ASTRASPX

TFE731*

 

 

FUEL CELL

FUEL LEAKING INTO CABIN. CUSTOMER SQKD FUEL SMELL INSIDE CABIN. REMOVED INTERIOR AND FLOOR PANELS AND FOUND ATTACHMENT BRACKETS MOUNTED INTO WING TANK (INCLUDING COLLECTOR BOX) FASTENERS LEAKING BADLY. DURING BOOST PUMP OPERATION, FUEL LEAK INCREASED TO COVER CENTER ISLE WITH FUEL. RESEALED FASTENERS IN CABIN AND INNER TANK. (K)

CA050815006

KAMOV

AMTR

 

FUEL CONTROL

FAILED

8/10/2005

KA32A1

KLIMOVK1A

 

HP3BMA

ENGINE

(CAN) WHILE ON APPROACH FOR LANDING, A HIGH ROTOR SPEED CONDITION OCCURED. THE PILOT IMMEDIATELY NOTICED THE INCREASE IN NR AND INCREASED COLLECTIVE TO MAINTAIN THE NR WITHIN NORMAL PARAMETERS. WITH THE NR STABILIZED, THE DEFECTIVE ENGINE WAS IDENTIFIED AND THE THROTTLE CONTROL LEVER WAS RETARDED. THE AIRCRAFT DESCENDED AND CARRIED OUT AN UNEVENTFUL LANDING. ONCE ON THE GROUND, A SEPARATE ENGINE CHECK IDENTIFIED THE NR 2 ENGINE FCU NF GOVERNOR HAD FAILED. THE FUEL CONTROL UNIT WAS REPLACED.

CA050809003

LEAR

GARRTT

 

CLAMP

LOOSE

8/4/2005

35LEAR

TFE73122B

 

420C75275M

BYPASS VALVE

(CAN) AT 38000 FEET THE LT FUEL COMPUTER WENT OFF LINE. SHORTLY AFTER THE RT COMPUTER WENT OFF LINE. THIS WAS FOLLOWED BY EXCESSIVELY HIGH TEMPERATURE BUILDING IN THE CABIN WITH NO CONTROL OF THE ENVIRONMENTAL SYSTEM. THE CREW DECIDED TO LAND. MAINTENANCE TROUBLESHOOTING REVEALED A CONNECTOR CLAMP FOR THE HOT AIR BYPASS VALVE HAD COME LOOSE. FURTHER INVESTIGATION FOUND 6 OUT OF 8 CLAMPS WERE LOOSE. THE CLAMPS WERE RE-TORQUED AND LEAK CHECKED SERVICEABLE LACK OF LOCK WIRE ON THE CLAMPS POSSIBLY CONTRIBUTED TO THIS OCCURRENCE. ALL CLAMPS WERE RE-CHECKED AND LOCK WIRED WHEN THE AIRCRAFT RETURNED TO BASE.

CA050816004

LEAR

GARRTT

 

ACTUATOR

FAILED

7/21/2005

45LEAR

TFE7312

 

6627401000007

HORIZONTAL STAB

(CAN) DURING CLIMB-OUT AFTER AUTO-PILOT WAS ENGAGED, THE AMBER PRIMARY PITCH TRIM FAIL EICAS MESSAGE CAME ON. SECONDARY TRIM WAS SELECTED AND USED FOR REMAINDER OF FLIGHT. MAINTENANCE TROUBLESHOOTING FOUND THAT THE AUTO-PILOT TRIM ACTIVATION CAUSED FAILURE OF PRIMARY TRIM SYSTEM. CHANGED HORIZONTAL STABILIZER TRIM ACTUATOR P/N 6627401000-007.

2005FA0001263

LEAR

GARRTT

 

WINDSHIELD

DELAMINATED

8/5/2005

55LEAR

TFE7313A

 

66004047

COCKPIT

WINDSHIELD HAS CONSIDERABLE DELAMINATIONS AT AREA BELOW DEFOG NOZZLE. DIMENSIONS OF AREA 3.5 INCH X 2 INCH. DEPTH OF DELAMINATIONS UP TO .125. THIS IS NOT THE FIRST WINDSHIELD FOUND IN THIS CONDITION. PROBABLE CAUSE IS ALCOHOL GETTING BETWEEN THE WINDSHIELD AND DEFOG ASSEMBLY. (K)

2005F00100

LKHEED

ALLSN

 

WHEEL

LOOSE

9/14/2005

P38L

V1710*

 

C20211170

MLG 

WHEEL ASSEMBLY RETURNED FOR LOOSE TIE BOLTS, OF 18 TIE BOLTS INSTALLED 2 ARE MISSING 11 ARE LOOSE. MFG HAS NOW ISSUED SL F6137-32-843 IN HOPES THIS WILL RESOLVE.

2005F00101

LKHEED

ALLSN

 

WHEEL

LOOSE

9/14/2005

P38L

V1710*

 

C20211170

 

WHEEL ASSEMBLY RETURNED FOR LOOSE TIE BOLTS, OF 18 TIE BOLTS INSTALLED 2 ARE MISSING 11 ARE LOOSE. MFG HAS NOW ISSUED SL F6137-32-843 IN HOPES THIS WILL RESOLVE.

0509137

LKHEED

PWA  

 

EXHAUST RISER

SEPARATED

9/6/2005

PV1  

R2800*

 

15070001

NR 5 

NR 5 EXHAUST RISER HAD SEPARATED FROM ENGINE JUST BELOW THE FLANGE WELD. THE OWNER STATED THIS WAS THE SECOND TIME THIS HAS HAPPENED IN 40 HOURS. REPLACED ALL 3 RISERS AND COLLECTOR.

2005FA0001288

MOONEY

CONT

 

WIRE HARNESS

BURNED

8/29/2005

M20R

IO550*

 

 

COCKPIT

WHEN TROUBLESHOOTING THE SQUAWK (RECOGNITION LIGHTS ON ALL THE TIME), FOUND CHARED WIRE INSULATION IN THE WIRE HARNESS FEEDING THE OVERHEAD BANK OF SWITCHES THAT CONTROL THE SHIPS EXTERIOR LIGHTING. TRACED THE CHARRED INSULATION TO AN OVERHEATED CONDITION IN THE RECOGNITION LIGHT CIRCUIT. A SUBSTANDARD CRIMP ON A WIRE TERMINAL WAS REPAIRED AND THE OVERHEATED CONDITION WAS NOT NOTED AFTER THAT. THE (LIGHTS ON ALL THE TIME) SQUAWK WAS DUE TO THE CHARRED INSULATION ALLOWING POWER DIRECTLY TO THE RECOG LIGHTS, CIRCUMVENTING THE SWITCH. (K)

2005FA0001301

PARTEN

LYC  

 

LIFTER

BROKEN

9/9/2005

P68C

IO360A1B6

 

72877

ENGINE

UPON COMPLYING WITH SB, VALVE GUIDE INSPECTION, FOUND LIFTER BODY PN 72877 BROKEN. VALVE GUIDE REVEALED NO SIGNS OF STICKING. (K)

2005FA0001300

PARTEN

LYC  

 

VALVE GUIDE

STUCK

9/9/2005

P68C

IO360A1B6

 

72897

EXHAUST VALVE

DURING LANDING, RT POSITION ENGINE EXPERIENCED ROUGHNESS. FOUND CYLINDER NR 2 EXHAUST VALVE STUCK. VALVE GUIDE INSPECTIONS ARE DUE AT 1000 HOURS. ENGINE ONLY HAD 842.6 HRS. (K)

CA050829002

PIAGIO

PWA  

 

WIRE

BURNED

8/25/2005

P180

PT6A66

 

K61 

WINDSHIELD HEAT

(CAN) CO-PILOTS WINDSHIELD, NR 4 AREA, FAILED ON LOW SELECTION. HIGH HEAT WAS SELECTED AND ELECTRICAL BURNED SMELL WAS DETECTED. SYSTEM WAS SHUTOFF AND TRIP CONTINUED WITHOUT INCIDENT. MAINTENANCE TROUBLESHOOTING FOUND THE PROBLEM TO BE RELAY K61 WHEN IT WAS LOCATED THE WIRE FROM RELAY TO WINDSHIELD WAS FOUND BURNED AND LOOSE ON THE RELAY. THE WIRE WAS REPLACED AND SYSTEM TESTED AND RETURNED TO SERVICE.

CA050805003

PIPER

LYC  

LYC  

BAFFLE

WARPED

8/3/2005

PA18

O320A2B

3241

 

MUFFLER

(CAN) EXCESSIVE EXHAUST BACK PRESSURE - MUFFLER 2 INCH STACK HOLE IN CAN 1.5 INCH DIAMETER LEFT A HIGH RESTRICTION CAUSING HIGH HEAT PROGRESSIVELY COLLAPSING THE PERFORATED BAFFLE AROUND THE EMERGECY BAIL RESULTING IN A SERIOUS LOSS OF POWER.

2005FA0001284

PIPER

LYC  

PRESTOLITE

WIRE

CHAFED

9/8/2005

PA23250

TIO540*

 

PF-14-16

ALTERNATOR

LT ALT NR1 FAILED. REPAIRED WIRING CONNECTIONS, REPLACED ALT AND REG. LT ALT NR 2 FAILED ON T/O. FOUND FIELD WIRE SEG INNER INSULATION CRACKED, BARE UNDER SHIELDING. HEATSHRINK TUBING ADDED TO MAKE INSTALLATION NEATER, FORCED SHIELDING INTO CONTACT WITH PRIMARY CONDUCTOR BRINGING FIELD TO GROUND. SPLICED IN NEW WIRE SEG. LT ALT NR3 FAILED AFTER 2 FLIGHTS. FOUND FIELD WIRE SEG PF-14-16 AT WING CNTR LAYING ON BELLY SKIN AND CHAFED THROUGH. WING CNTR DID NOT HAVE STRAIN RELIEF BACKSHELL INSTALLED,WAS NOT SECURED AWAY FROM SKIN. CHAFED AREA WAS 2 INCHES OF CONNECTOR. SPLICED NEW WIRE SEG, SECURED WIRE BUNDLE CLEAR OF SKIN. REPLACED ALT (INSTALLED NR 4) AND REG. FIELD WIRE IS NOT PROTECTED BY A FUSE OR CB.

2005FA0001216

PIPER

LYC  

 

TRANSMISSION

FAILED

8/5/2005

PA24

O360*

 

2572000

MLG 

LANDING GEAR RETRACT SYS WOULD NOT EXTEND GEAR TO A DOWN AND LOCKED POSITION. SEVERAL ATTEMPTS TO CYCLE GEAR POPPED GEAR MOTOR CIRCUIT BREAKER. TRANSMISSION DECOUPLER RELEASED WHEN EMERGENCY GEAR EXTENSION WAS ATTEMPTED, GEAR WOULD NOT GO TO DOWN AND LOCKED POSITION. PILOTS ATTEMPT TO RECYCLE GEAR TO THE RETRACTED POSITION AND THEN TO EXTENDED POSITION AFTER EMERGENCY GEAR EXTENSION WAS ACTUATED, ADDED TO PROBLEM, TRANSMSN DECOUPLER WAS IN DIRECT CONTACT WITH GEAR THROUGH BOLT, MAKING EXTENSION IMPROBABLE. SITUATION MAKES POSSIBILITY OF GEAR EXTENSION NEARLY IMPOSSIBLE BECAUSE THE THROUGH BOLT CANNOT TRAVEL FAR ENOUGH BACK TO GET DOWN AND LOCKED CONDITION.

2005FA0001223

PIPER

LYC  

 

PLACARD

MISINSTALLED

8/5/2005

PA24260

TIO540*

 

 

SWITCH

WHEN DOING OPERATIONAL CHECK AFTER INSTALLATION OF SVS VI UPGRADE KIT ON SVA IA SYSTEM, (AD 2005-11-05). THE ON/OFF PLACARD ON ON/OFF LEVER WAS CONFUSING. WHEN LEVER VALVE WAS ON OR OPEN, IT LOOKED AS IF IT WERE (OFF) OR CLOSED ON THE PLACARD. (K)

2005FA0001247

PIPER

LYC  

 

FILTER

CONTAMINATED

7/29/2005

PA24260

TIO540*

 

 

FUEL SYSTEM

THIS STATION RECEIVED REQUEST FROM REGULAR CUSTOMER, THAT WAS FERRYING AIRCRAFT. AIRCRAFT ENGINE FAILED TO MAKE FULL POWER THEN QUIT ON GROUND. CREW WAS SENT TO REMOTE AIRFIELD TO TROUBLESHOOT. AFTER EXTENSIVE TROUBLESHOOTING, FOUND FUEL INJECTORS CLOGGED BY DIRT. FUEL FILTER SCREEN AND FILTER REMOVED AND FOUND BADLY CONTAMINATED. (PHOTO) AIRCRAFT HAD JUST RECEIVED A FRESH ANNUAL INSP. FILTRS AND NOZZLES WERE CLEANED, FUEL LINES PURGED AND ENGINE RUN MADE FULL POWER. FILTERS THEN CHECKED AGAIN AND WERE CLEAN AT THIS TIME. POOR MAINT AND INSP DETERMINED TO MAJOR FACTOR CONTRIBUTING TO MALFUNCTION. EXPERIENCED PILOT RECONIZED PROBLEM ENGINE COULD HAVE FAILED WHILE AIRBORNE. (K)

CA050802003

PIPER

LYC  

PREAIR

VENTURI

MISMANUFACTURED

8/2/2005

PA28140

O320E3D

MA4SPA

46F10

CARBURETOR

(CAN) INSPECTION PRIOR TO ASSEMBLY REVEALED SERIOUS CASTING FLAW IN PART.

2005FA0001214

PIPER

ROTAX

 

HINGE BRACKET

CRACKED

8/8/2005

PA28140

ROTAX582

 

 

ELEVATOR

DURING INSPECTION, IT WAS NOTED THAT THE ELEVTOR FORWARD HINGE ATTACH BRACKET WAS CRACKED AT THE AFT BEND IN THE RADIUS NEAR THE AFT ATTACH RIVET. THE OWNER STATED THAT THIS WAS A COMMON OCCURANCE ON THESE MODEL AC AND THAT 2 OTHERS WERE KNOWN. (K)

2005FA0001231

PIPER

LYC  

 

CABLE

CHAFED

8/8/2005

PA28181

O360*

 

7814039

BATTERY

DURING ROUTINE MAINTENANCE, FOUND BATTERY POS CABLE BEING CHAFED ON CONTROL CABLE TURNBUCKLE IT CAME IN CONTACT WITH. THE SAWING MOTION OF THE TURNBUCKLE ALMOST WORE THRU THE BATTERY CABLE INSULATION JACKET. THE CABLE WAS REROUTED (REPOSITIONED) AT LAST 100 HR FOR THE SAME REASON. THE CABLE HAS TAKEN A SET AND KEEPS RETURNING TO ITS ORIGINAL BEND CONFIGURATION. RECOMMEND SHORTENING THE CABLE AND CRIMPING THE TERMINAL ENDS 90 DEGREES TO THE LAY OF THE CABLE. (K)

CA050829004

PIPER

LYC  

 

CRANKCASE

CRACKED

8/23/2005

PA28R200

IO360C1C

 

 

ENGINE

(CAN) ON INSPECTION, CHECKING FOR OIL LEAK, A CRACK IN THE CRANKCASE WAS FOUND. FRONT LT SIDE FORWARD OF NR 2 CYLINDER.

CA050817006

PIPER

LYC  

 

SKIN

DAMAGED

7/14/2005

PA31325

TIO540F2BD

 

 

FUSELAGE

(CAN) WHILE IN CRUISE FLIGHT THE NR 2 COMM ANTENNA DEPARTED THE AIRCRAFT. THE PILOT HEARD THE ANTENNA DEPART AND LANDED AT THE NEAREST AIRPORT. A FERRY PERMIT WAS OBTAINED AND FOLLOWING INSPECTION THE AIRCRAFT WAS FERRIED TO FLY WERE IT WAS RECENTLY REPAIRED. THE ATTACH SCREWS WERE FOUND TO HAVE PULLED THROUGH THE SKIN BUT NO APPARENT REASON FOR THIS WAS FOUND. THE SKIN WAS REPAIRED AND THE ANTENNA DOUBLER WAS REPLACED ALONG WITH THE ANTENNA AND THE AIRCRAFT WAS RETURNED TO SERVICE.

CA050722011

PIPER

LYC  

 

DOOR

MISSING

7/21/2005

PA31350

TIO540J2BD

 

40979

EMERGENCY EXIT

(CAN) AT APPROXIMATELY 0022Z ON JULY 21, 2005 THE AIRCRAFT WAS ON DESCENT FROM 8,500 THROUGH 7,500 FEET, WHEN THE EMERGENCY EXIT DISENGAGED AND FLEW OFF THE AIRCRAFT.AIRSPEED WAS BETWEEN 175 AND 185 KTS. THERE WAS APPARENTLY NO SOUND PRIOR TO TH E DISENGAGEMENT OR AFTER THE DISENGAGEMENT TO INDICATE FUSELAGE OR CONTROL SURFACE IMPACT. THE AIRCRAFT FLEW A STABILIZED APPROACH TO RUNWAY 29 AND LANDED UNEVENTFULLY. THERE WAS ONE PASSENGER ON BOARD AT THE TIME. THE EMERGENCY EXIT CAME OFF OVER A DENSELY WOODED AREA AND HAS NOT BEEN RETRIEVED. THE AIRCRAFT WAS INSPECTED FOR OTHER INCIDENTAL DAMAGE AND NONE WAS FOUND. THE LATCHING MECHANISM WAS INSPECTED AND FOUND TO CONFORM TO CORRECT OPERATION AND RIGGING IAW MANUFACTURERS SPECIFICATIONS.

CA050811002

PIPER

LYC  

PIPER

ADAPTER

MISSING

8/4/2005

PA31350

TIO540J2BD

 

557003

FUEL TANK COVER

(CAN) THE AIRCRAFT HAD JUST TAKEN OFF WHEN THE PILOTS NOTICED THAT THE LT MAIN FUEL CAP HAD DEPARTED THE AIRCRAFT. THE AIRCRAFT RETURNED TO BASE WITHOUT INCIDENT. IN ORDER TO PREVENT THE AIRCRAFT FROM BEING ACCIDENTALLY FUELED WITH TURBO FUEL, MFG PROVIDES A KIT WITH AN ADAPTER RING TO NARROW THE OPENING TO THE FUEL TANK (SB 797B). IN THIS CASE THE FUEL CAP AND THE ADAPTER RING IT LOCKS INTO WERE MISSING.

2005FA0001281

PIPER

LYC  

 

SWITCH

OPEN

8/23/2005

PA31P

TIGO541*

 

587817

CABIN DOOR

CONFIRMED REPORT OF CABIN DOOR UNSAFE ANNUNCIATOR REMAINING ILLUMINATED W/DOOR CLOSED. FOUND UPPER CENTER BAYONET RECEPTACLE SWITCH TO HAVE OPEN CONTINUITY IN ANY POSITION. FOUND WIRE L11T PREVIOUSLY JUMPERED TO DOOR SEAL PRESSURE SWITCH GROUND AND DOOR WARNING RELAY JUMPERED AROUND FROM L11T CONNECTION TO GROUND CONNECTION BY PERSONS OR FACILITY UNKNOWN. NO RECORDS IN US AC LOGBOOKS OF REPAIRS IN THIS AREA. REPLACED BAYONET SWITCH W/NEW SWITCH AND REPAIRED/CORRECTED SYSTEM WIRING TO AS SHOWN IN SRM WIRING DIAGRAMS. DOOR WARNING ANNUNCIATOR OPERATIONAL CHECKS NOW NORMAL. (K)

CA050808005

PIPER

PWA  

 

HOSE

LEAKING

8/4/2005

PA31T

PT6A28

 

1776604

NLG 

(CAN) AFTER TAKEOFF THE NOSE LANDING GEAR WOULD NOT RETRACT FULLY. THE CREW THEN SELECTED GEAR DOWN, GEAR WOULD NOT LOCK DOWN. LANDING GEAR HAD TO BE MANUALLY PUMPED DOWN IN ORDER TO GET THREE GREEN LIGHTS. THE NOSE GEAR ACTUATOR RETRACT FLEXHOSE WAS FOUND LEAKING. THE HOSE WAS REPLACED WITH A SERVICEABLE UNIT, AND A SATISFACTORY GEAR SWING WAS CARRIED OUT.

2005FA0001211

PIPER

GARRTT

 

O-RING

CUT  

8/8/2005

PA421000

TPE33114

 

7503503AF

PROP DOME

AT THE OUTER MARKER ON APPROACH, THE PILOT NOTICED AN OIL ODOR IN THE ENVIRONMENTAL SYSTEM. THE AIRCRAFT LANDED WITHOUT INCIDENT. POST FLIGHT WALK AROUND REVEALED OIL LEAK AT THE RT PROPELLER. MAINTENANCE WAS DISPATCHED AND INVESTIGATION REVEALED THE RT PROPELLER DOME PISTON O-RING WAS CUT/ROLLED. THE O-RING WAS REPLACED AND THE AIRCRAFT WAS RETURNED TO SERVICE. (K)

2005FA0001253

PIPER

LYC  

 

STARTER

BROKEN

8/29/2005

PA44180

O360A1H

 

MX6220

RT ENGINE

PILOT ATTEMPTED START BUT STARTER WOULD NOT CRANK. UPON VISUAL INSP OF STARTER FOUND BENDIX HAD STUCK IN THE EXTENDED POSITION ON THE PREVIOS START CAUSINING THE GEAR TO BREAK AND BREAKING 2 MOUNTING PADS OF THE BENDIX HOUSING. DAMAGE WAS ALSO NOTED ON THE ENGINE RING GEAR. STARTER AND RING GEAR REPLACED AND AIRCRAFT RETURNED TO SERVICE.

CA050830002

PIPER

LYC  

 

ROD END

BROKEN

8/23/2005

PA44180

O360E1A6

 

37722002

MLG DOOR

(CAN) LINKAGE CRACK AT WELD JOINT AT LT MAIN LANDING DOOR ATTACHMENT. PARTS REPLACED. GEAR RETRACTION C/O. NO PROBLEM FOUND.

2005FA0001256

PIPER

LYC  

 

VALVE

DEFECTIVE

8/12/2005

PA46350P

TIO540*

 

1H2418

DE-ICE SYSTEM

DE-ICE PRESSURE MANIFOLD VALVE DEFECTIVE IAW SL. (K)

2005FA0001271

PIPER

 

 

COLLAR

SEPARATED

11/18/2004

PA60601P

 

 

 

MLG STRUT

COLLAR SEPARATING FROM TUBE DUE TO INSUFFICIENT PENETRATION WHEN PART WAS FURNACE BRAZED OR SILVER SOLDERED TOGETHER, WORKING COLLAR CAUSED PART TO WORK AND CRACKED BOSS. RECOMMEND INSPECTION OF COLLAR AT BOTTOM OF GEAR STRUT FOR ANY MOVEMENT OR WORKING BETWEEN COLLAR AND THE STRUT CYLINDER ASSY - DYE CHECK WHERE PART IS MACHINED FOR CLEARANCE ON TORQUE LINKS. (K)

CA050823008

ROBSIN

LYC  

 

ALTERNATOR

FAILED

8/22/2005

R44  

O540F1B5

 

ALX8421LS

ENGINE

(CAN) TWO BLADES LET GO ON THE COOLING FAN OF THE ALTERNATOR. PILOT DISCOVERED THIS DURING HIS DAILY INSPECTION. ONE OF THE BLADES WAS LODGED IN THE LOWER ENGINE COWL. THE SECOND BLADE WAS NOT FOUND. NO DAMAGE WAS FOUND ON ANY OTHER AREA OF THE AIRCRAFT.

CA050824011

SKRSKY

PWA  

 

LINE

CRACKED

8/20/2005

S64E

JFTD12A4A

 

575776

ENGINE OIL

(CAN) AC WAS INVOLVED IN LOGGING OPS. AS AC WAS APPROACHING LOG LANDING, PILOTS WERE NOTIFIED THAT WHITE SMOKE WAS COMING FROM NR 2 ENG. AC PROCEEDED TO SERVICE LANDING TO HAVE MAINT CREW LOOK AT PROBLEM. ENROUTE, COPILOT NOTICED WHITE SMOKE COMING FROM ENG WAS INCREASING. COMMAND PILOT ELECTED TO CARRY OUT AN INFLIGHT SHUTDOWN OF NR2 ENG AS A PRECAUTIONARY MEASURE. AC CONTINUED ON TO ITS SERVICE LANDING AND MADE A SINGLE ENGINE LANDING. UPON INSPECTION OF ENG, MAINT CREW DISCOVERED THAT OIL TUBE RUNNING FROM ENG OIL PUMP TO OIL COOLER HAD DEVELOPED CRACK AT B-NUT ATTACHMENT END OF TUBE. ENGINE HAD NOT BEEN STARVED OF OIL. TUBE WAS REPLACED, OIL RESERVOIR WAS REPLENISHED, AC WAS RETURNED TO SERVICE.

AMCR200500007

SKRSKY

PWA  

 

ATTACH FITTING

BROKEN

8/29/2005

S76B

PT6*

 

7620902019045

MLG DOOR

AFTER LANDING, CREW FOUND RT MAIN GEAR DOOR RESTING ON LANDING GEAR. FOUND DOOR ATTACH BRACKET BROKEN.

CA050719003

SNIAS

TMECA

 

BRACKET

CRACKED

7/2/2005

AS332L

MAKILA1A

332A31000106

332A67145620

M/R HEAD DEICE

(CAN) THE DEICE EQUIPMENT WAS BEING REMOVED FOR THE SUMMER SEASON,WHEN THIS CRACK WAS DISCOVERED. NO PREVIOUS EVIDENCE WAS DISCOVERED CONCERNING THIS PART.THIS CRACK WAS DISCOVERED VISUALLY DURING THE REMOVAL.

CA050819004

SNIAS

TMECA

 

IGNITER

DAMAGED

8/19/2005

AS350B

ARRIEL1B

 

9550175400

ENGINE

(CAN) INSULATION TIP LOOSE. HASN'T FALLEN OUT YET. ANOTHER OPERATOR HAS HAD TWO OCCURANCE'S WHERE THE CERAMIC INSULATOR CAME RIGHT OUT.

CA050819005

SNIAS

TMECA

 

IGNITER

DAMAGED

8/19/2005

AS350B

ARRIEL1B

 

9550175400

ENGINE

(CAN) INSULATION TIP LOOSE. HASN'T FALLEN OUT YET. ANOTHER OPERATOR HAS HAD TWO OCCURANCE'S WERE THE CERAMIC INSULATOR CAME RIGHT OUT.

CA050725003

SWRNGN

GARRTT

 

CARRIER ASSY

CRACKED

7/20/2005

SA226TC

TPE33110UA

 

8679225

PLANETARY GEAR

(CAN) DURING ENGINE TREND RECORDING BY THE FLIGHT CREW IT WAS NOTICED THAT THE LH ENGINE OIL PRESSURE INDICTION HAD DECREASED 15 PSI WITHIN A WEEK OF OPERATION. UPON ARRIVAL MAINTENACE WAS ADVISED AND ELECTED TO REMOVE THE ENGINE FOR INSPECTION. UPON INSPECTION OF THE PLANETARY CARRIER ASSY IT WAS OBVIOUSLY FRACTURED AND PIECES OF THE OIL DISTRIBUTION GALLERIES MISSING. EXCESSIVE WEAR ON THE PLANETARY GEARS WAS ALSO EVIDENT. THE ENGINE WAS REPLACED. THIS CARRIER HAD 381 HRS SINCE OVERHAUL AND WAS INSPECTED USING LPI PRIOR TO INSTALLATION ONTO THE ENGINE, NO CRACKS WERE DETECTED. THIS IS THE SIXTH PLANETARY CARRIER FAILURE SUFFERED BY THIS OPERATOR.

CA050804010

SWRNGN

GARRTT

 

RELEASE CABLE

SHEARED

8/2/2005

SA226TC

TPE33110UA

 

21032031

EMER MLG RELEASE

(CAN) WHEN COMPLYING WITH AN UNRELATED INSPECTION UNDER THE COCKPIT FLOOR, MAINTENANCE DISCOVERED THE NOSE LANDING GEAR EMERGENCY RELEASE CABLE WAS SHEARED AT THE CLEVIS WHERE IT ATTACHES TO THE HANDLE BELLCRANK. THIS AIRCAFT HAD RECENTLY (WITHIN 50 HOURS) UNDERGONE A PHASE 5 INSPECTION WHERE THE SYSTEM WAS INSPECTED AND TESTED, NO DEFECTS WERE FOUND. THE CABLE WAS REPLACED WITH A SERVICEABLE UNIT, GEAR SWINGS WERE CONDUCTED AND NO FURTHER FAULTS FOUND. THIS IS THE FIRST FAILURE OF THIS TYPE THIS OPERATOR HAS EXPERIENCED.

CA050725007

SWRNGN

GARRTT

 

FCU  

LEAKING

7/21/2005

SA226TC

TPE33110UA

 

89356117

LT ENGINE

(CAN) UPON LANDING AND SHUTDOWN OF THE LT ENGINE IT WAS NOTICED THAT THE OVERBOARD ENGINE DRAIN FOR THE FUEL CONTROL UNIT WAS LEAKING FUEL. THE FUEL CONTROL WAS REPLACED. THE LAST TIME THIS FCU WAS REPAIRED IT WAS FOR THE SAME FUEL LEAK PROBLEM IN MARCH OF 2001.

CA050817003

SWRNGN

GARRTT

 

PRESSURE SWITCH

FRACTURED

8/14/2005

SA227AC

TPE33111U

 

31057463

ENGINE NOSE CASE

(CAN) OIL LEAK NOTICED FROM ENGINE COWL AFTER LANDING. SWITCH WAS BROKEN OFF OF NTS SWITCH HOUSING ON RT SIDE OF NOSE CASE. BROKEN BETWEEN FITTING END AND NUT PART, WHERE THE WRENCH WOULD BE USED TO SECURE IT. NEW SWITCH INSTALLED AND GROUND CHECKED SERVICIBLE AND AIRCRAFT RETURNED TO SERVICE

CA050822003

SWRNGN

GARRTT

 

ENGINE

MAKING METAL

8/18/2005

SA227AC

TPE33111U

 

 

 

(CAN) UPON TAKEOFF BEFORE ROTATION, CHIP LIGHT STARTED TO FLICKER. TAKEOFF ABORTED AND RETURNED TO TERMINAL. MAINTENANCE FOUND BRASS COLORED METAL IN OIL. ENGINE REPLACED.

CA050804005

ZLIN

LYC  

 

CONTROL CABLE

FRAYED

6/23/2005

Z242L

AEIO360A1B6

 

Z4243130000

TE FLAPS

(CAN) DURING A 100 HR INSPECTION THE FLAP CONTROL SYSTEM CENTER CABLE WAS DISCOVERED TO BE FRAYED AT THE AREA OF THE PULLEY. THE CABLE WAS REPLACED NEW.

CA050804006

ZLIN

LYC  

 

CONTROL CABLE

FRAYED

6/23/2005

Z242L

AEIO360A1B6

 

Z4243130000

TE FLAPS

(CAN) DURING A 100 HR INSPECTION THE FLAP CONTROL SYSTEM CENTER CABLE WAS DISCOVERED TO BE FRAYED AT THE AREA OF THE PULLEY. THE CABLE WAS REPLACED NEW.

CA050804008

ZLIN

LYC  

 

CONTROL CABLE

FRAYED

7/26/2005

Z242L

AEIO360A1B6

 

Z4243130000

TE FLAPS

(CAN) DURING A 100 HR INSPECTION THE CENTER FLAP CABLE WAS FOUND TO BE FRAYED AT THE PULLEY AREA. THE CABLE WAS REPLACED NEW. THIS IS A COMMON AREA FOR WEAR ON THESE CABLES.

 

END OF REPORTS