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

314

bald eagle watching over three eggs

SEPTEMBER

2004

 


CONTENTS

AIRPLANES

BEECH......................................................................................................................................... 1

CESSNA...................................................................................................................................... 2

HELICOPTERS

AUGUSTA................................................................................................................................... 2

MCDONNELL DOUGLAS......................................................................................................... 3

POWERPLANTS AND PROPELLERS

FACET AEROSPACE PRODUCTS............................................................................................ 3

HARTZELL.................................................................................................................................. 3

MCCAULEY............................................................................................................................... 4

TELEDYNE CONTINENTAL..................................................................................................... 4

ACCESSORIES

AMER-KING............................................................................................................................... 4

 

AIR NOTES

SPECIAL AIRWORTHINESS INFORMATION BULLETIN (SAIB)........................................ 5

ELECTRONIC VERSION OF FAA FORM 8010-4, MALFUNCTION OR
DEFECT REPORT....................................................................................................................... 6

PAPER COPY OF FAA FORM 8010-4, MALFUNCTION OR DEFECT REPORT................. 6

INTERNET SERVICE DIFFICULTY REPORTING (iSDR) WEB SITE..................................... 6

IF YOU WANT TO CONTACT US........................................................................................... 7

AVIATION SERVICE DIFFICULTY REPORTS........................................................................ 7

 


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 and thereby cooperate 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 Malfunction or Defect Reports. 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.

 

AIRPLANES

BEECH

Beech; Model C90; Cabin Door Broken Clevis Pin; ATA 5210

Pilot reported a loud noise coming from the cabin door followed by rapid de-pressurization.

An inspection revealed the door had a broken clevis pin (P/N 131323-2C17) in the linkage going to the forward upper latch hook.

According to the submitter, the latch hook and linkage in this area are on a replacement schedule required in accordance with Raytheon M/M chapter 5-11-00 for continued airworthiness. This aircraft had not reached the point of replacement.

A search of the FAA Service Difficulty Reporting System data base revealed five other occurrences from October 1996, to April 2004, of broken or sheared clevis pins in this area. One report noted depressurization as a result of a broken clevis pin.

Part total time: 9,559.5 hours.

 

Beech; Model 95-B55; Shorted Ignition Vibrator; ATA 7413

During a maintenance test flight, the pilot noticed a burning odor. He turned base leg to land on the departure runway and subsequently landed with the gear up. After he exited the aircraft, he noticed a fire in the pilot side rudder pedals area and extinguished it. Upon further investigation, he discovered the ignition vibrator (P/N 10-357487-242) had shorted out and caused the fire behind the instrument panel.

According to the submitter, the Beech Baron Model 55 shop manual serial numbers TC-1 through TC-1028 do not have circuit protection in the ignition circuit. The ignition vibrator has 28 volts applied at all times. The switch provides the ground to complete the circuit. Any malfunction of the switch or a short in the wiring would cause the points to close and the ignition vibrator to be active. Aircraft after serial number TC-1029 have a 5 amp circuit breaker in this circuit. There is not a Service Bulletin or Airworthiness Directive note to retro-fit a circuit breaker to the earlier serial-numbered aircraft.

Part total time: 4,704.8 hours.

 


CESSNA

Cessna; Model 172RG; Main Landing Gear Pivot Assembly Failure; ATA 3230

During flight, the left hand landing gear would not come down. The pilot was able to manually lower the gear down and locked.

Upon investigation, the technician discovered the left main landing gear pivot assembly shaft (P/N 2441100-1) had broken where the actuator attaches. When the gear was selected to the down position, the actuator could not move the left hand gear. It appears the shaft material was flawed at manufacturing. Over time, the shaft cracked halfway around the circumference, which caused the final failure of the shaft.

The submitter suggested the part 91 operators should be required to remove the gear to conduct a detailed inspection. The area of failure on this pivot assembly could only be seen after removing the landing gear.

A search of the FAA Service Difficulty Reporting System data base revealed 21 pivot assemblies installed on other aircraft were cracked, sheared, or broken. The dates of occurrences are as follows:

October 1995 (3 reported)       October 1996                   June 2001

March 1996                            January 1997                   July 2001 (2 reported)

May 1996                               April 1997                       September 2001

June 1996                               June 1997                        January 2002

August 1996                           May 2000                        April 2002

September 1996                      April 2001 (2 reported)

Part total time: unknown.

 

Cessna; Model 551; Boost Pump Wiring; ATA 2897

While complying with Service Bulletin (SB) 550-28-14, the technician discovered the fuel boost pump wiring inside the left and right wing tanks had rubbed holes in the fuel transfer lines, which are inside the tanks, and damaged the wiring. The SB addresses this concern and provides instructions for securing the boost pump wiring.

The submitter stated this is a mandatory SB only and that they have heard of operators that have been unwilling to do this SB because it is not associated with an Airworthiness Directive (AD) at this time.

Part total time: unknown.

 

HELICOPTERS

AUGUSTA

Augusta; Model A109K2; Tail Rotor Trunnion Heat Damage; ATA 6420

During a daily inspection, the mechanic noted excessive play in tail rotor hub in the trunnion area.

The mechanic removed the rotor hub for inspection and discovered a soft face mallet was required to free the trunnion (PN 109-0131-05-115) from the tail rotor gearbox output shaft. After removing the trunnion, he found signs of excessive heat discoloration on the paint/coating. The trunnion bushings/races were loose and would slide half way off of the trunnion.

On June 7, 2003, an Augusta A109K2 was demolished. The helicopter had an uncontrolled collision with the ground during a climb to cruise. Witnesses observed the tail rotor separating from the aircraft. The tail rotor trunnion was found in two pieces. The accident resulted in two injuries and one fatality.


A search of the FAA Service Difficulty Reporting System data base revealed six Augusta A109K2 with damaged trunnions, three had heat damage, two were significantly worn, and one was pitted. The damaged trunnions were not the same part numbers as the one previously mentioned.

Part total time: 10.3 hours.

 

MCDONNELL DOUGLAS

McDonnell Douglas; Model 520N; Fan Gearbox Mount Alignment; ATA 6510

The technician discovered the fan-control rod and the fan driveshaft made contact. The contact may have caused high vibration in the airframe.

The technician called McDonnell Douglas to check the alignment of the fan mount. Upon removal, paint inside the mast was blistered and falling down inside the M/R gearbox.

According to the submitter, this is the second time he has had driveshaft rub since this aircraft was new. He also stated that this problem has occurred nine other times in the last 4 years.

Part total time: 1,543.8 hours.

Time since overhaul: new.

 

POWERPLANTS AND PROPELLERS

FACET AEROSPACE PRODUCTS

Facet Aerospace Products; Model MA-4SPA; Float Leaking; ATA 7322

This aircraft engine has experienced two fires. Both fires resulted in carburetor failure caused by a split float. The submitter stated a previous Airworthiness Directive (AD) should have solved this problem.

The “new” float split filled with fuel and the engine quit. The aircraft was being used during an instructional flight with two pilots onboard. During restart procedures, which were conducted on the active runway, the aircraft caught fire.

The submitter was unsure if this was an overhauled or newly built carburetor.

Part total time: 281 hours.

 

HARTZELL

Hartzell; Model HC-A3VF4; Propeller Blade Cracked; ATA 6111

The technician conducted an inspection required by Airworthiness Directive (AD) 97-18-02. Using the phase analysis eddy current inspection technique on the propeller blade (P/N 8433-4), he discovered cracks. Both blades contained several small cracks not detectable using an ED520 or similar meter-based instruments.

The submitter recommended that technicians consider upgrading to phase sensitive instrumentation when performing inspections.

A search of the FAA Service Difficulty Reporting System data base revealed two other reports where propeller blades with the same part number have cracked.

Part total time: unknown.

 


MCCAULEY

McCauley; Model D2A34C98; Propeller Hub Threads Cracked; ATA 6114

While complying with an Airworthiness Directive (AD), the submitter filled the propeller with oil. He sent the propeller to the propeller shop due to red dye leakage. During the inspection, the propeller shop discovered the threaded retention hub was cracked across the threads at the crank flange side.

The submitter reported two other occurrences of problems with this propeller hub part number.

A search of the FAA Service Difficulty Reporting System data base revealed no other occurrences of this problem.

Part total time: unknown.

 

TELEDYNE CONTINENTAL

Teledyne Continental; Model IO550-B; Cylinder Head Cracks; ATA 8530

The submitter stated that he performed routine engine cylinder compression check as required per annual inspection procedures. Per Teledyne Continental specifications, the number one cylinder and the number three cylinder passed the compression minimums with the number one as 66/80 and the number three as 51/80.

During the compression check, the technician observed air escaping from the area of the fuel injectors of each cylinder. Upon further inspection, he saw cracks between the barrel and the head between two cooling fins. The compression checks for all other cylinders passed with no external leaks noted.

The submitter’s inspection department researched this problem and discovered that Airworthiness Directive (AD) 86-13-04R1 does not specifically reference this engine serial number; however, the AD does contain failures very similar to this failure.

AD 86-13-04R3, dated November 10, 1987, does not include the serial number of this engine, however, the AD does state, in part, that this AD applies to cylinder assemblies (part number (P/N) stamped on flange of cylinder) with P/Ns 643985, 646100, 646101, 646652, 646652CP, 646657, 646657CP, 649162, 649162CP, 649169, and 649169CP including all these numbers with all “A” dash numbers as a suffix, and also any cylinder reworked from the above part numbers, either of which were manufactured on or after January 1, 1985, with 485 total hours or less installed on, but not limited to the engines listed in this AD. This AD is available at the following website: http://www.airweb.faa.gov/Regulatory_and_Guidance_Library/rgAD.nsf/0/8FDD529EDEF00A43862568410053D46C?OpenDocument

The submitter did not provide the part number of the cylinders affected.

Part total time: 1,378.1 hours.

 

ACCESSORIES

AMERI-KING

Ameri-King; Model AK-450; ELT Antenna Shaft Breaking; ATA 2562

During flight, the ELT antenna shaft is breaking off at the base and the antenna is being lost. The base that connects it to the coax is still on the plane. The center shaft, which is the actual antenna, is held in place with a jam-type locking feature. The antenna rod is crimped to a pin, which makes contact with the coax lead.


The submitter stated he has replaced six antennas that lost continuity or were completely gone after the aircraft lands.

The submitter stated in the case of an accident, the ELT would only be dead weight. There is a possibility that a very weak signal could be transmitted. He recommended checking the continuity between the antenna and the connection on the ELT unit.

A search of the FAA Service Difficulty Reporting System data base revealed only one other report of the antenna falling off. However there are 21 records submitted that state that the Ameri-King ELT has problems transmitting a signal.

Part total time: unknown.

 

AIR NOTES

SPECIAL AIRWORTHINESS INFORMATION BULLETIN (SAIB)

(This SAIB is printed as it was received.)

Introduction:
This Special Airworthiness Information Bulletin (SAIB) alerts part 135 and 91 Air Operators, Repair Stations, Mechanics holding Inspector Authorization (IA), Fixed Base Operators and all inspectors of the Flight Standards District Offices (FSDO) to the existence and use of unapproved life rafts in aircraft. During the investigation of three related Suspected Unapproved Parts (SUP) cases, this office has become increasingly aware of widespread use of non-TSO life rafts in both 14CFR part 135 and part 91 aircraft, especially in south Florida.

Simply stated, the certification requirements for U.S. civil aircraft describe, “When its intended purpose is for emergency equipment, that equipment must be approved”. This statement applies, regardless of the requirement to carry or not to carry a life raft on the aircraft.

Background:
Non-TSO life rafts and emergency equipment kits, manufactured and distributed by Survival Products of Hollywood, Fl and others, do not meet the minimum TSO requirements and are not approved for use on any aircraft. Examples of non-conformity are, they may not have multiple chamber construction, lack the required freeboard when loaded and lack required buoyancy in partially inflated condition. These unapproved rafts are advertised on the internet as acceptable (approved) for use on “private” aircraft and “marine” use, when neither the FAA nor the U.S. Coast Guard has issued them approvals. These unapproved rafts have been sold to part 135 Air Operators, found on part 135 aircraft in service during FAA surveillance and are available for sale and rent at Fixed Base Operators and “Pilot Shops”.

The following survival products, Inc, non-TSO life rafts and emergency equipment kits have been found on aircraft in addition to being for sale and rent:

·                Life rafts; P/N 1400-1, 1400-3, RAF1104-101, 1900-1, 1900-3, 1900-1/2000-1, 1900-1/2000-3 & 1900-1/200-5

·                Survival kits; P/N 1500-1, 1500-3 & 1500-5

There are additional non-TSO life raft manufacturers making their products available on the aviation market, although none have been found on aircraft or for rent during our investigations.

Recommendation:
Each person should inspect their life raft and emergency equipment kit in use or available for use on any aircraft, to ensure it is clearly marked FAA-TSO. In addition, that it is newly manufactured or has been inspected and approved for return to service by its original manufacturer or an FAA approved repair station. Any non-TSO life raft or emergency equipment kit, regardless of its manufacturer, should be removed from service and clearly marked, “NOT FOR USE ON AIRCRAFT”.


FOR FURTHER INFORMATION, CONTACT:
Richard Shaffer, Principal Maintenance Inspector, FSDO-17, 1050 Lee Wagener Blvd., Ft. Lauderdale, Fl. 33315; telephone (954) 635-1347; or (954) 635-1300; fax (954) 635-1260; e-mail Richard D Shaffer@faa.gov

 

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) data base 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), Maintenance Difficulty Reports (MDRs), 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 data base contains records dating back to 1974. At the current time, we are receiving approximately 45,000 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: John Jackson (405) 954-6486
FAX: (405) 954-4570 or (405) 954-4655
Technical support provided by: Aero Tech Service Associates

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 between July 23, 2004, and August 2, 2004, which have been entered into the FAA Service Difficulty Reporting (SDR) System data base. 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

AUS20040395

 

 

 

LIFE RAFT

DAMAGED

5/11/2004

 

 

 

710FAUL2901104

CABIN

(AUS) LIFERAFT HOLED IN TOP, ROOF AND FLOOR CHAMBERS. INVESTIGATION FOUND THE HOLES HAD OCCURRED DURING INITIAL PACKING AT MANUFACTURE.

CA040310007

 

 

 

BATTERY  

LEAKING

3/8/2004

 

 

 

 

LIFEJACKET LIGHT

(CAN) SEALED BATTERIES ARE INTEGRAL PART OF SURVIVOR LIGHT IN AVIATION LIFEJACKET. LIFEJACKET AND LIGHT IS USED AS PART OF HELICOPTER PASSENGER TRANSPORTATION SUIT SYSTEM APPROVED TO CAN/CGSBS-65.17-99. SEVERAL BATTERIES IN THIS LOT NUMBER HAVE BEEN LEAKING AND SOME HAVE BEEN DIM OR FAILED TO FUNCTION WHEN TESTED. STORAGE LIFE IS STATED AS 60 MONTHS. HAVE NOT YET CONFIRMED THE NATURE OF THE LEAKING SUBSTANCE. WE ARE REMOVING ALL OF THE LIGHTS OF THIS BATCH DESIGNATION FROM SERVICE. APPROXIMATELY 100 LIGHTS IN TOTAL. BATTERY ONLY 16 MONTH.

CA040525004

 

 

HARTZL

SEAL

CUT  

5/25/2004

 

 

HCB3TN3

45C33173472

PISTON

(CAN) PROPELLER WAS SENT IN FOR AN OIL LEAK, AND UPON DISASSEMBLY INNER SURFACE OF THE PISTON SEAL WAS FOUND TO BE CUT. THE SEAL WAS REPLACED PROPELLER TESTED FOR LEAKS, AND THE PROPELLER WAS RETURNED TO THE CUSTOMER

CA040709001

 

LYC  

 

CYLINDER

FAILED

6/29/2004

 

O320*

 

SL32006WA21P

ENGINE

(CAN) NEW CYLINDER ASSEMBLIES (2), REMOVED FROM BOXES AND INSPECTED/MEASURED TO FIT RINGS. BARRELS FOUND TO BE AT SERICE LIMIT WITH .010' CHOKE AND .008' TO .010' OUTOF ROUND. NEW CYLINDERS OUT OF LIMITS. NO APPARENT PHYSICAL DAMAGE, QUALITY CONTROL PROBLEM.

CA040505004

 

PWA  

 

RETAINING RING

COLLAPSED

4/30/2004

 

PT6A114A

 

3020159

TURBINE SHROUD

(CAN) THE HOT SECTION WAS GIVEN A SCHEDULED BORESCOPE INSPECTION. CT SHROUD SEGMENTS HAD SHIFTED AXIALLY. DISMANTLE SHOWED THE RETAINING RING TO HAVE DISTORTED AND BECOME DISLOCATED. THIS PROBLEM HAS BEEN DOCUMENTED ON OTHER ENGINES. MFG HAS ISSUED P/N 3110741-02 RETAINING RING ON SB 13121 (60A, 61, 62, 65 SERIES) AND SB 3248 (41/42, 45 SERIES) TO PREVENT THE COLLAPSE OF THE RETAINING RING. THE LATTER SB HAS NOT BEEN ISSUED ON SMALLER ENGINE MODELS SUCH AS THE 114A ENGINE MODEL TO ALLOW THE MORE ROBUST RETAINING RING TO BE USED.

CA040609012

AEROSP

PWA  

BFGOODRICH

FILTER

FAILED

6/6/2004

ATR42300

PW120

 

5905587

FUEL PUMP

(CAN) ON TAKEOFF, THE CREW OBSERVED A FUEL FILTER CAUTION ON NR 1 ENGINE. THE AIRCRAFT RETURNED TO POINT OF DEPARTURE. MAINTENANCE REPLACED THE HIGH PRESSURE FILTER ON THE ENGINE PUMP AND THE AIRCRAFT WAS RETURNED TO SERVICE.

CA040414005

AEROSP

PWA  

 

FILTER

CONTAMINATED

9/21/2003

ATR72201

PW124B

 

 

FUEL PUMP

(CAN) DURING CLIMB, ENGINE ITT ROSE AND ENGINE WAS UNRESPONSIVE TO TLA INPUT. ENGINE WAS SHUT DOWN AND AN UNEVENTFUL SINGLE ENGINE LANDING WAS MADE. POST EVENT EXAMINATION SHOWED THAT METERING VALVE OF THE HMU WAS JAMMED BY A PIECE OF EPOXY MATERIAL. BORE (DOWNSTREAM) SURFACE OF FUEL FILTER SHOWED AN LARGE DEPOSIT OF EPOXY, WHICH APPARENTLY WAS AN EXCESS OVERFLOW OF MATERIAL USED TO SECURE END CAPS TO BARREL OF FILTER. FURTHER INVESTIGATION BY THE SUPPLIER OF THE PUMP ASSEMBLY HAS SHOWN THAT INCIDENT FILTER, WHILE MARKED TO BE VERY SIMILAR TO THAT OF SUPPLIER, WAS NOT, IN FACT, MADE BY SUPPLIER. SUPPLIER HAVE ISSUED INSTRUCTIONS TO FIELD TO INSPECT PW100 FILTERS FOR POSSIBLE PRESENCE OF EPOXY IN BORE OF UNIT.

CA040413008

AIRBUS

 

 

CDU  

SMOKE

4/7/2004

A310300

 

 

4043912902

COCKPIT

(CAN) DURING TAXIING TO THE GATE, AIRCRAFT EXPERIENCED SMOKE IN THE FLIGHT DECK CAUSED BY NR 2 FMS CDU. NR 2 CDU WAS CONFIRMED FAULTY AFTER MAINTENANCE INVESTIGATION AND THE AIRCRAFT WAS DISPATCHED UNDER MEL. CDU WAS REPLACED ON RETURN FLIGHT AND ROUTED TO VENDOR FOR INVESTIGATION. TSSV:1861 HRS.

CA040413003

AIRBUS

GE  

 

ACCESS DOOR

MISSING

4/7/2004

A310300

CF680C2A5

 

A52475147012

LAV SERVICING

(CAN) THE AIRCRAFT ARRIVED AT THE STATION WITH THE MID LAVATORY SERVICING ACCESS DOOR MISSING. THE AIRCRAFT WAS DISPATCHED UNDER CDL AND A NEW DOOR WAS INSTALLED AT THE MAIN BASE. THE LAVATORY SYSTEM WAS CHECKED SERVICEABLE (NO LEAK). SUSPECT PANEL NOT PROPERLY LATCHED AT THE PREVIOUS STATION.

CA040603005

AIRBUS

GE  

 

WIRE

CHAFED

6/2/2004

A310304

CF680C2A5

 

EO266QF16

FUEL PUMP

(CAN) AIRCRAFT ARRIVED WITH THE RT OUTER TANK FUEL PUMP NR 1 LOW PRESSURE LIGHT ON. FOLLOWING TROUBLE SHOOTING, THE WIRE FOR NR 1 RT OUTER PUMP WAS FOUND SHORTED IN THE CONDUIT AT REAR SPAR WS 915.0. WIRE WAS REPLACED. MFG WAS ADVISED OF THIS PROBLEM. A CAMPAIGN HAS BEEN INITIATED TO INSPECT REAR SPAR WIRING ON ALL OF THESE MODELS.

CA040412007

AIRBUS

CFMINT

 

STEERING SYS

MALFUNCTIONED

4/12/2004

A319114

CFM565A1

 

 

NLG 

(CAN) FAULT: ON APPROACH AFTER PUTTING THE LANDING GEAR DOWN, THERE WAS AN ECAM MSG REF. TO NOSE WHEEL STEERING FAULT. AC CARRIED OUT A MISSED APPROACH AND WENT THROUGH THE QRH. ACTION: TOWER CALLED OUT THE EMERGENCY EQUIPMENT FOR THE LANDING. AC LANDED ON 24L, AFTER LANDING, THE AC WAS ABLE TO TAXI TO THE RAMP. (AC REMOVED FROM SERVICE FOR N/W STEERING INVEST.)

CA040602007

AIRBUS

CFMINT

 

WINDSHIELD

FAILED

6/19/2004

A320211

CFM565A1

 

NP1653114

COCKPIT

(CAN) WINDSHIELD OUTER PANE SHATTERED ONLY, AIR TURNBACK WINDSHIELD REPLACED WINDSHIELD HAD 21,599 HRS.

CA040326005

AIRBUS

RROYCE

 

SLIDE

LEAKING

3/25/2004

A330342

RB211TRENT77

 

7A1510110

CABIN

(CAN) FOLLOWING A SLIDE RAFT DEPLOYMENT TEST, FOUND SLIDE RAFT DEFLATING AT SLOW RATE BY A PIN HOLE. PIN HOLE LOCATE ON FORWARD TUBULAR SECTION AT APPROXIMATELY 4 FEET FROM GROUND. DEFECT IS UNDER INVESTIGATION WITH ENGINEERING AND VENDOR.

CA040609010

AMD  

GE  

 

ENGINE

FLAMED OUT

5/27/2004

FALCON20D5

CF7002D2

 

 

NR 1 

(CAN) ON CLIMB OUT FROM XXX TO RL350 THE NR 1 ENGINE (S/N 245U150) EXPERIENCED A FLAME-OUT. CREW WAS ABLE TO RE-LIGHT THE ENGINE AND RETURN WITHOUT FURTHER INCIDENTS. ON 26 MAY 04, ANOTHER CREW HAD EXPERIENCED A FLAMEOUT. THE FCU WAS SUBSQUENTLY CHANGED, AIRCRAFT WAS GROUND RUN AND CHECKED SERVICEABLE. WITH SECOND FLAMEOUT (ON 27 MAY) ENGINE HAS BEEN REMOVED AND WILL BE ROUTED TO OVERHAUL SHOP FOR FURTHER ANALYSIS. FINDINGS, REPORT TO FOLLOW.

CA040609008

AMD  

GARRTT

 

PRESSURE SWITCH

MALFUNCTIONED

6/7/2004

FALCON900

TFE7315BR

 

8G12561

FUEL SYSTEM

(CAN) DURING WALK AROUND AFTER COMPLETION OF A FLIGHT, NOTICED FUEL LEAKING OUT OF BOTTOM OF NR 1 ENGINE COWLING. FOUND NR 1 FUEL PRESSURE SWITCH LEAKING OUT OF VENT HOLE. SWITCH WAS REPLACED WITH A NEW UNIT AND TESTED OK.

CA040430005

BAC  

LYC  

 

WHEEL

BROKEN

4/17/2004

146200A

ALF502R5

 

AHA1483

MLG 

(CAN) ENGINEERS RETURNING TO HANGAR FROM LINE, CAME UPON A PIECE OF DEBRIS ON APRON TO HANGAR. THEY RETRIEVED THE OBJECT AND FOUND THAT IT WAS A 10-INCH SECTION OF A WHEEL BEAD FLANGE. AC HAD BEEN OUT FOR ENGINE RUNS AFTER AN ENGINE CHANGE AND WAS IN THE HANGAR, IT WAS CHECKED AND FOUND TO HAVE A SECTION OF THE NR 2 MAIN WHEEL P/N AHA1489 OB FLANGE MISSING. THE OUTER WHEEL HALF P/N AHA1483 IS FOUND IN THE MFG CMM IPL 32-42-59 FIG NR 1 ITEM NR 160. THIS WHEEL WAS ON BUILD 17 AND HAD BEEN NDT AT THAT TIME WITH NO DEFECTS NOTED AT THE TIME. THE WHEEL WAS REPLACED AND THE WHEEL HALF HAS BEEN SENT TO MFG FOR ANAYLSIS. WE WILL FOLLOW-UP ON THE INCIDENT ONCE WE HEAR BACK FROM THE MANUFACTURER WITH THEIR FINDINGS.

AUS20040317

BAC  

LYC  

 

SHAFT

WRONG PART

4/27/2004

146200A

ALF502R5

 

 

ANTISKID SYS

(AUS) NR 1 MAIN WHEEL TIRE DAMAGED AND DEFLATED. INVESTIGATION FOUND THAT THE TIRE DEFLATED DUE TO WHEEL LOCKUP ON LANDING ROLL. THE WHEEL LOCKUP WAS CAUSED BY A BENT ANTI-SKID TRANSDUCER DRIVESHAFT WHICH CAUSED THE ANTI-SKID SYSTEM ON THIS WHEEL POSITION TO BE NON-OPERATIVE. THE BENT TRANSDUCER SHAFT ALSO CAUSED DAMAGE TO SEVERAL OTHER COMPONENTS NAMELY THE BRAKE COOLING FAN MOTOR, FAN DUCT, AND DEBRIS SCREEN COVER. THE BENT ANTI-SKID DRIVE SHAFT APPEARS TO BE CAUSED BY INCORRECT FIT OF SHAFT INTO DEBRIS SCREEN SPLINED DRIVE BEARING AT LAST WHEEL INSTALLATION. PERSONNEL/MAINTENANCE ERROR.

AUS20040322

BAC  

LYC  

 

PTU  

SEIZED

3/19/2004

146200A

ALF502R5

 

4204001

HYDRAULIC SYSTEM

(AUS) HYDRAULIC POWER TRANSFER UNIT (PTU) SEIZED.

CA040603001

BAC  

LYC  

 

GOVERNOR

FAILED

6/1/2004

146200A

ALF502R5

 

230305204

OVERSPEED

(CAN) DURING PILOT OPERATIONAL CHECK, NR 4 ENGINE DID NOT SHUT DOWN WITH THE OVERSPEED STOP. NR 4 ENGINE OVERSPEED CONTROLLER REPLACED AND NR 4 ENGINE OVERSPEED TEST CARRIED OUT IAW AMM 71-00-00 BLOCK 501. TEST COMPLETED AS SERVICEABLE AND AIRCRAFT WAS RETURNED TO SERVICE.

CA040601014

BAC  

LYC  

 

CONNECTOR

SHORTED

5/30/2004

146200A

ALF502R5

 

MS3476W1419S

NR 4 ENGINE

(CAN) UNCOMMANDED IN-FLIGHT SHUTDOWN OF NR 4 ENG. DURING FINAL APPROACH. CONNECTOR IDENT (P52) ON BACK-UP OVERSPEED CONTROLLER FOUND TO BE SHORTED INTERNALLY. VOLTAGE LEAKING ACROSS VARIOUS PINS ON PLUG ALSO OUT TO OVERSPEED FUEL BYPASS/SHUT-OFF VALVE. THIS IS WHAT ACTIVATED FUEL BYPASS VALVE, CAUSING ENG TO SHUTDOWN. REPLACING (P52) CONNECTOR (P/N MS3476W14-19S) WILL ALSO REPLACE SECONDARY/BACK-UP CONTROLLER AS PRECAUTIONARY MEASURE (TO HAVE IT BENCH CHECKED TO ENSURE THERE WAS NO INTERNAL DAMAGE CAUSED BY STRAY VOLTAGE). ONCE SYS IS RE-ASSEMBLED, WILL CARRY OUT FURTHER CHECKS TESTING. GROUND RUNS, CARRIED OUT FUNCTIONING OVERSPEED ON PARTICULAR ENG WITH NO FAULTS AND SYS WAS GROUND CHECKED SERVICEABLE.

AUS20040414

BAG  

LYC  

 

SEAL

LEAKING

5/15/2004

BAE146200A

ALF502R5

 

750470706

MLG ACTUATOR

(AUS) RT MAIN LANDING GEAR ACTUATOR RESTRICTOR SEAL LEAKING.

AUS20040429

BAG  

 

 

LINK

FRACTURED

5/17/2004

BAE146300A

 

 

HC321B0018000

MLG 

(AUS) MAIN LANDING GEAR ASSISTOR JACK TRIANGULAR LINK FAILED AT JACK ATTACHMENT POINT.

AUS20040410

BAG  

LYC  

 

INTERCOSTAL

CORRODED

5/17/2004

BAE146300A

ALF502R5

 

HC538J1324000

FUSELAGE

(AUS) AFT CABIN FLOOR INTERCOSTAL CONTAINED LEVEL 2 CORROSION ON THESIDE AND UPPER SURFACES. THE INTERCOSTAL DAMAGE WAS LOCATED INZONE 251 BETWEEN FRAMES 41 AND 53 AT BL9 LH. AREA OF CORROSION MEASURED 38.1MM (1.5 IN) IN LENGTH BY 3.175MM (0.125 IN) IN WIDTH AND 0.558MM (0.022 IN) DEPTH.

AUS20040405

BAG  

LYC  

 

FRAME

CORRODED

5/17/2004

BAE146300A

ALF502R5

 

HC538H0136002

FUSELAGE

(AUS) LT FUSELAGE FRAME 43 CONTAINED LEVEL 2 CORROSION ON THE FORWARD FACE AT FLOOR LEVEL. DAMAGE WAS LOCATED AT ZONE 20 FRAME 43 STA 726.9 AND WAS 38.1MM (1.5IN) LONG BY 38.1MM (1.5IN) WIDE AND 4.546MM (0.179IN) DEEP. CAUSE OF DAMAGE WAS ASSESSED AS ENVIRONMENTAL.

AUS20040401

BAG  

LYC  

 

ACTUATOR

SEIZED

5/17/2004

BAE146300A

ALF502R5

 

P308450102ISS2

DRAG CONTROL

(AUS) RT NR 2 LIFT SPOILER ACTUATOR SPINDLE SEIZED IN LOCKED POSITION WITH THE ACTUATOR EXTENDED. FOUND DURING INSPECTION IAW AD/BA6-27-60-16D BAE MANDATORY ISB 27-137.

AUS20040339

BAG  

LYC  

 

PLATE

CORRODED

5/5/2004

BAE146300A

ALF502R5

 

 

FUSELAGE

(AUS) INSP OF REAR CABIN WET AREA AT FLOOR LEVEL FOUND CORROSION IN FOLLOWING PLATES: SHEAR PLATE PN HC538H1183-000 LOCATED ON TOP OF LONGITUDINAL BEAM FRAME 43 RBL 34. CORROSION WAS LOCATED ON UPPER SURFACE MEASURING 17.018MM (0.67IN) LENGTH, 16.002MM (0.63IN) WIDTH AND 0.508MM (0.020IN) DEPTH. TOP PLATE PN HC 538J0584-203 LOCATED ON TOP OF LONGITUDINAL RAIL FROM FRAME 41 TO 43 RBL 21. CORROSION LOCATED ON LOWER SURFACE MEASURING 24MM (0.944IN) LENGTH, 18MM (0.708IN) WIDTH AND 0.838MM (0.033IN) DEPTH. TOP PLATE PN HC538J1361-000 OF LATERAL FLOOR SUPPORT BEAM AT FRAME 40 BETWEEN LBL 20 + RBL 20. CORROSION LOCATED ON THE UPPER SURFACE MEASURING 250MM (9.8IN) LENGTH, 45MM 040339 5.

AUS20040345

BAG  

LYC  

 

BOLT

CORRODED

5/6/2004

BAE146300A

ALF502R5

 

HC536B0475000

FUSELAGE

(AUS) FORWARD OUTER ATTACHMENT SPECIAL BOLT SHAFT CORRODED AND PLATING MISSING. CORROSION WAS LOCATED APPROXIMATELY 12.7MM (0.5IN) DOWN FROM THE BOLT HEAD. AREA OF CORROSION 25.4MM (1IN) IN LENGTH BY 9.39MM (0.370IN) IN WIDTH BY0.127MM (0.005IN) DEPTH.BOLTS ARE LOCATED IN ZONE 161, FRAME 29 STN 539-4.

AUS20040351

BAG  

LYC  

 

SEAT TRACK

CORRODED

5/6/2004

BAE146300A

ALF502R5

 

 

FUSELAGE

(AUS) SEAT TRACKS CORRODED. PN HC538J0343-001 RT IB SEAT TRACK FOUND CORRODED ON UPPER SURFACE. CORROSION MEASURES 106.68MM (4.2IN) LENGTH, 24.13MM (0.95IN) WIDTH WITH DEPTH OUT OF LIMITS. LOCATION, ZONE 251, FRAME 40, RBL 21 RT. REPORTED CAUSE OF DEFECT, LAVATORY/GALLEY SPILL. PN HC539J0395 LT OB SEAT TRACK FOUND CORRODED ON THE UPPER SURFACE. CORROSION MEASURES 38.1MM (1.5IN) LENGTH, 21.7MM (0.856IN) WIDTH AND 1.803MM (0.071) DEPTH. LOCATION - ZONE 251 STA 867 AND 854 LBL 43. REPORTED CAUSE OF DEFECT - DISSIMILAR METALS OF THE SEAT TRACK AND THE STEEL FEET OF THE MEAL TROLLEY REAR STOWAGE UNIT IN A DAMP ENVIRONMENT. PN HC538J0343-000 LT IB SEAT TRACK FOUND CORRODED ON.

AUS20040357

BAG  

LYC  

 

FRAME

CRACKED

5/5/2004

BAE146300A

ALF502R5

 

HC536H1050200

FUSELAGE

(AUS) CABIN CROWN FRAME TO SKIN STRUCTURE ANGLE CLEATS (8OFF) CRACKED FROM BEND RADIUS EDGE. THE ANGLE CLEATS ARE LOCATED IN FOLLOWING AREAS: FRAME 19A BETWEEN STRINGERS 1 AND 2 LT. FRAME 19A BETWEEN STRINGERS 2 AND 3 LT 3. FRAME 19B BETWEEN STRINGERS 1 AND 2 LT. FRAME 19B BETWEEN STRINGERS 2 AND 3 LT. FRAME 19C BETWEEN STRINGERS 1 AND 2 LT. FRAME 19C BETWEEN STRINGERS 2 AND 3 LT. FRAME 19D BETWEEN STRINGERS 1 AND 2 LT. FRAME 19D BETWEEN STRINGERS 2 AND 3 LT THE CRACKS RANGED IN LENGTH BETWEEN 2.5MM (0.1IN) AND 22.8MM(0.9IN).

AUS20040372

BAG  

LYC  

 

ANGLE

CORRODED

5/7/2004

BAE146300A

ALF502R5

 

HC538H0125007

FUSELAGE

(AUS) RT REAR ENTRY SILL PLATE ATTACHMENT ANGLE CONTAINED LEVEL 2 CORROSION ON THE UPPER SURFACE. AREA OF CORROSION 48.26MM (1.9IN) LONG BY 20.8MM (0.82IN) WIDE AND 0.584MM (0.023IN) DEEP. LOCATION OF CORROSION, ZONE 252 STRINGER 19, BETWEEN FRAMES 41AND 43, BL44 RT.

AUS20040444

BAG  

LYC  

 

COMPUTER

FAULTY

5/20/2004

BAE146300A

LF5071H

 

676801007

TE FLAPS

(AUS) FLAP COMPUTER FAULTY.

AUS20040436

BAG  

 

 

TORQUE TUBE

CRACKED

4/1/2004

JETSTM4112

 

 

AHA1899

BRAKE

(AUS) BRAKE ASSEMBLY TORQUE TUBE CONTAINED NUMEROUS CRACKS IN TENON SLOTS. FOUND USING FLUORESCENT MAGNETIC PARTICLE INSPECTION. CRACKS WERE FOUND UP TO APPROXIMATELY 6.35MM (0.25IN) IN LENGTH. BRAKE IS FROM A REGISTERED AIRCRAFT. BRAKE HAD BEEN REMOVED DUE TO RUBBING ON AXLE AND CONTACT WITH WHEEL HUB CAUSING DAMAGE.

CA040519013

BEECH

PWA  

 

FITTING

CRACKED

5/15/2004

100BEECH

PT6A28

 

501200735

FUSELAGE

(CAN) DURING THE ROUTINE COMPLETION OF CF1981-35 SITES NR 1 AND NR 2, A SMALL CRACK WAS DISCOVERED ON THE LOWER RT, IB BATHTUB FITTING. THE CRACK APPEARED TO START ON THE FEATHERED EDGE AT THE CENTER OF THE RADIUS AND PROPOGATE TOWARD THE MATING SURFACE OF THE FITTING FOR A DISTANCE OF APPROXIMATELY 0.164 INCH. MFG WAS CONSULTED AND A REPAIR WAS GENERATED THROUGH THEIR REPAIR DESIGN OFFICE. IT CONSISTED OF BLENDING OUT THE CRACK TO THE SPECIFIED DIMENSIONS, PERFORMING FPI TO ENSURE ALL THE CRACK WAS REMOVED AND SURFACE TREATING THE ALUMINUM TO PREVENT CORROSION. THE WING BOLT WAS REINSTALLED IAW SIRM AND THE AIRCRAFT RELEASED FOR SERVICE.

CA040412011

BEECH

PWA  

 

SHAFT

BROKEN

4/9/2004

1900D

PT6A67D

 

1013800001

TE FLAP CONTROL

(CAN) DURING THE REPLACEMENT OF A FLAP ACTUATOR AND DURING TESTING, THE NR 4 FLAP PANEL CEASED TO MOVE. IT WAS FOUND THAT THE FLAP FLEXIBLE SHAFT HAD INTERNALLY CORRODED AND FAILED. THIS ISSUE WAS FOUND ONCE PRIOR UNDER SDR NR 20030825014 BUT WITHOUT THE EVIDENCE OF CLAMP INTERFERENCE. WATER HAS ONCE AGAIN FOUND ITS WAY INAND STAYED IN THE LOW POINT OF THE CABLE. THE CABLE WAS REPLACED AND THE SYSTEM CHECKED OK. MFG HAS ONCE AGAIN BEEN NOTIFIED OF THIS CONDITION.

CA040412012

BEECH

PWA  

 

BEARING

FAILED

4/9/2004

1900D

PT6A67D

 

114800893

MLG WHEEL

(CAN) DURING TAKEOFF, THE CREW WAS NOTIFIED THAT NR 3 WHEEL HAD SEPARATED FROM THE AIRCRAFT. THE BEARING HAD FAILED WHICH ALLOWED THE WHEEL ASSY TO PASS OVER THE RETENTION NUT AND SEPARATE. DUE TO PAST ISSUES WITH BEARING FAILURES, A GREASE ANALYSIS HAS BEEN CONDUCTED SINCE MARCH 19, 2004 DUE TO ON GOING ISSUES WITH AEROSHELL 22 AND 5 WHEEL BEARING GREASE. OUR TEST INDICATED THAT A SWITCH TO MOBIL SHC100 IS IN ORDER AND THE FLEET WILL BE SWITCHED OVER EXPEDIOUSLY.

CA040503002

BEECH

PWA  

 

ACTUATOR

FAILED

4/8/2004

200BEECH

PT6A41

 

508202085

MLG 

(CAN) DURING TROUBLESHOOTING OF A LANDING GEAR PROBLEM WE NOTICED THAT THE NUT ASSEMBLY IN THE NOSE GEAR ACTUATOR COULD MOVE A SMALL AMOUNT FROM SIDE TO SIDE PLAY IN THE HOUSING. THE ACTUATOR WAS REMOVED AND WE NOTICED THAT THE MECHANISM WAS A LITTLE ROUGH WHEN TURNED BY HAND. THE ACTUATOR WAS RETURNED TO THE OVERHAUL SHOP FOR FURTHER INVESTIGATION. THE OVERHAUL SHOP HAS RESPONDED: UNIT FAILED THE END PLAY TEST AND SCREW/NUT ASSEMBLY SEEMED TO HAVE SOME SIDE TO SIDE PLAY. DISASSEMBLED, INSPECTED, NDT, ECT FOUND: SCREW ASSEMBLY / NUT ASSEMBLY OUT-OF-LIMITS. HOUSING HAS DEEP CORROSION PITTING IN BOLT HOLE BOSS .THIS ACTUATOR WAS OVERHAULED IN APRIL 2003 AND ONLY HAD 819 CYCLES SINCE THEN.

CA040526007

BEECH

PWA  

 

MOTOR

FAILED

5/19/2004

200BEECH

PT6A41

 

 

MLG 

(CAN) ON APPROACH, CREW SELECTED LANDING TO EXTEND. LANDING GEAR WOULD NOT EXTEND. GEAR HANDLE CYCLED. STILL NO GEAR EXTENSION. CREW CARRIED OUT LANDING GEAR EMERGENCY EXTENSION. NO FURTHER FAULTS. MAINTENANCE FOUND LANDING GEAR ELECTRIC MOTOR PREMATURELY FAILED. REPLACE ELECTRIC MOTOR . NO FURTHER FAULTS.

CA040607003

BEECH

PWA  

 

LANDING GEAR

MALFUNCTIONED

3/2/2004

200BEECH

PT6A41

 

 

 

(CAN) DURING FLIGHT, THE LANDING GEAR TOOK LONGER THAN NORMAL TO RETRACT. COULD NOT DUPLICATE THE PROBLEM IN THE HANGAR EVEN WHEN SWINGING THE GEAR.

AUS20040373

BEECH

PWA  

 

SPAR CAP

CORRODED

5/7/2004

200BEECH

PT6A41

 

1016200143

HORIZONTAL STAB

(AUS) RT HORIZONTAL STABILISER UPPER REAR SPAR CAP CONTAINED SEVERE INTERGRANNULAR CORROSION.

AUS20040435

BEECH

PWA  

 

CLIP

CRACKED

3/30/2004

200BEECH

PT6A42

 

35115396

TE FLAPS

(AUS) LT OB FLAP IB TRACK RIVETS LOOSE IN AREA ADJACENT TO LOWER SKIN ATTACHMENT. FURTHER INSPECTION FOUND BUCKLING AND CRACKING OF THE OUTBOARD SHEAR CLIP.

AUS20040454

BEECH

PWA  

 

ENGINE

OVERHEATED

4/11/2004

200BEECH

PT6A42

 

3030700

RIGHT

(AUS) RT ENGINE OVERTEMPED ON START. ENGINE REMOVED.

AUS20040452

BEECH

CONT

 

MOTOR

FAULTY

5/19/2004

58  

IO520*

 

27D39

BLOWER

(AUS) CABIN HEATER BLOWER MOTOR FAULTY. MOTOR WAS VIBRATING AND PRODUCING SMOKE.

AUS20040173

BEECH

CONT

 

WIRE

WRONG PART

2/23/2004

95C55

IO520C

 

 

ELEVATOR TAB ST

(AUS) RT ELEVATOR TRIM TAB HINGE WIRE MANUFACTURED FROM MILD STEEL. RT TRIM TAB FREEPLAY 7.366MM (0.290IN) AND LT TRIM TAB FREEPLAY 9.829MM (0.387IN). MAXIMUM FREEPLAY 2.133MM (0.084IN). PERSONNEL/MAINTENANCE ERROR. UNAPPROVED PART.

CA040513008

BEECH

PWA  

 

SPRING

DAMAGED

5/12/2004

99  

PT6A20

 

901187263

POWER CONTROL

(CAN) ON TAKE OFF ROLL, PWR WAS SET TO 1290 FOOT POUNDS. AFTER ROTATION PILOT NOTICED TORQUE WAS INCREASING ON RT ENG. FO ATTEMPTED TO REDUCE PWR BUT PWR LEVER WOULD NOT MOVE. TORQUE INCREASED TO APPROX 1500 FOOT LBS FOR ABOUT 90 SECONDS. AFTER REACHING SAFE ALTITUDE RT ENG WAS SHUT DOWN AND AC LANDED SAFELY. ON INSPECT ENG CNTRLS, PWR CNTRL SPRING LINK WAS FOUND TO BE CATCHING ON CNTRL LEVER MNTG BRKT. THIS LINK IS AT BASE OF ROD END THAT ATTACHES AIRFRAME PWR CABLE TO INPUT ARM ON CAM CLUSTER. ACTION OF LINK ON CNTRL LEVER BRACKET WOULD BE TO PULL PWR LEVER TOWARDS HIGHER PWR SETTING, ULTIMATELY JAM THERE. THIS LINK SHOULD HAVE BEEN MOUNTED 10-15 DEGREES FURTHER IN COUNTER CLOCKWISE DIRECTION ON PWR CABLE.

CA040604009

BEECH

PWA  

 

ADAPTER

CRACKED

6/2/2004

A100

PT6A28

 

 

P2.5 BLEED SYS

(CAN) DURING A ROUTINE HOT SECTION INSPECTION MAINTENANCE FOUND THE P2.5 BLEED ADAPTER (LOCATED AT APPROXIMATELY 1 O'CLOCK ON THE GAS GENERATOR CASE) WITH OBVIOUS CRACKS. THE RETAINING LUGS WERE BOTH CRACKED AND ONE OF THE ADAPTER WELDING JOINTS WAS CRACKED ON A LENGTH OF APPROXIMATELY 1.5 INCHES. THE ENGINE WAS SENT OUT FOR REPAIR AND HAS SINCE BEEN REINSTALLED AND PUT BACK INTO SERVICE.

CA040329002

BEECH

PWA  

BEECH

RIB  

CRACKED

3/18/2004

A100

PT6A28

 

115620010325

HORIZONTAL STAB

(CAN) ON INSPECTION OF THE HORIZONTAL STABILIZER THE UPPER SKIN WAS FOUND TO BE OIL CANNING. UPON FURTHER INSPECTION IT WAS FOUND THAT 6 RIBS WERE CRACKED INTERNALLY (PN 115-620010-325, 115-620010-210, 115-620010-355, 115-620010-255, 115-620010-215, 115-620010-209). WE BELIEVE THIS DAMAGE WAS FROM PEOPLE WALKING ON THE STABILIZER.

CA040608002

BEECH

PWA  

 

TORQUE TUBE

OUT OF LIMITS

6/3/2004

A100

PT6A28

 

1156100103

ELEVATOR

(CAN) DURING THE INSTALLATION OF A NEW ELEVATOR TORQUE TUBE, IT WAS NOTICED THAT ONE OF THE TAPERED PINS WAS INSTALLED BEYOND THE MANUFACTURES LIMITS. THE MM 27-30-00 PAGE 202 A, STATES IN PART THE SMALL END OF THE TAPER PIN BODY SHOULD EXTEND .000 TO 0.060 INCH BEYOND THE SURFACE OF THE SUPPORT. IF THE DIMENSIONS ARE NOT MET, NEW PARTS WILL BE REQUIRED. THE SMALL END ON THE SUBJECT TUBES EXTENDED 0.125 INCHES BEYOND THE SURFACE. A SECOND TORQUE TUBE FROM OUR STOCK WAS ALSO FOUND IN THE SAME CONDITION. BOTH TUBES WERE NEW, SUPPLIED BY THE AIRCRAFT MFG. A THIRD TUBE FROM THE SAME BATCH WAS REMOVED FROM OUR STOCK. MFG WAS CONTACTED AND THEY WILL BE INVESTIGATING THE MATTER FURTHER.

CA040329004

BEECH

LYC  

 

GOVERNOR

RUPTURED

3/16/2004

A65  

IGSO480A1E6

 

210385

PROPELLER

(CAN) THE OIL LEAK WAS TRACED TO THE PROP GOVERNOR AND ONLY SHOWED UP AT APPROXIMATELY 2500 RPM. A PIECE OF GASKET .1250 INCH WIDE WAS FOUND MISSING FROM THE GASKET WHICH CAUSED A LEAK OF AN ESTIMATED 1 QUART OF OIL EVERY 2 MINUTES. NO APPARENT REASON COULD BE FOUND FOR THE DEFECT. THE GASKET WAS DESTORYED IN THE PROCESS OF REMOVAL. AS IT WAS STUCK, THE MATING SURFACES HAD NO DEFECTS AND HOLD DOWN NUTS WERE TIGHT. NEW GASKET INSTALLED AND GROUND RUNS CARRIED OUT WITH NO LEAKS.

CA040505002

BEECH

PWA  

 

HOSE

RUPTURED

4/28/2004

B200

PT6A42

 

1013800153

BRAKE DEICE

(CAN) BRAKE DEICE HOSE RUPTURED AND CAUSED BLEED AIR FAILURE SYSTEM TO ACTIVATE LIGHT. HOSE WAS REMOVED AND LINE CAPPED, WARNING SYSTEM REPAIRED IAW MFG MM. CH.21. BRAKE HOSE ORDERED AND SYSTEM PLACARDED AND MADE INOPERATIVE.

AUS20040433

BEECH

PWA  

 

SEAL

WORN

5/20/2004

B200C

PT6A42

 

3022376

ENGINE

(AUS) ENGINE ACCESSORY GEARBOX STARTER-GENERATOR DRIVE SHAFT SEAL WORN. LOSS OF ENGINE OIL.

CA040624001

BEECH

PWA  

 

MOUNT

MISMANUFACTURED

6/17/2004

B200C

PT6A42

 

R2070011

ENGINE

(CAN) DURING ENGINE MOUNT REPLACEMENT IT WAS NOTICED THAT THE NEW MOUNTS WERE MANUFACTURED WITH THE BEVEL ON THE WRONG SIDE OF THE METAL PART OF THE CORE (R20700-11). THE CORE IS MADE OF RUBBER SANDWICHED BETWEEN TWO PIECES OF METAL. THE BEVEL IS THERE TO ALLOW THE INSERTION OF THE HAT BUSHING, THESE PARTS ARE ASSEMBLED WITH AN INTERFERENCE FIT, WITHOUT THE BEVEL IT IS VERY DIFFICULT/ IMPOSSIBLE TO INSERT THE BUSHING. STOCK WAS CHECK AND THREE MORE KITS WERE FOUND IN THE SAME CONDITION. THE PARTS WERE REJECTED.

AUS20040400

BEECH

PWA  

 

TURBINE BLADES

CRACKED

5/12/2004

B200C

PT6A42

 

312313102

TURBINE SECTION

(AUS) COMPRESSOR TURBINE BLADES (3 OFF) CRACKED. CRACKS EMANATE FROM BLADE TIP RADIALLY TOWARDS BLADE ROOT. CRACK LENGTHS UP TO APPROXIMATELY 7MM (0.27IN). FOUND DURING BOROSCOPE INSPECTION.

CA040609009

BEECH

PWA  

 

CONNECTOR

CORRODED

6/9/2004

B300B350C

PT6A60A

 

M817141120D

FUEL PROBE

(CAN) LT WING AUX FUEL TANK INDICATION ALWAYS INDICATING (0). WHEN TESTING SYSTEM LT QUANTITY CAUTION LIGHT WON'T COME ON. DURING TROUBLESHOOTING, FOUND A LOT WATER TRAPPED UNDER THE ACCESS PANEL AND THE WIRING WAS CORRODED. WATER REMOVED AND CONNECTOR WILL BE REPLACED.

CA040503001

BEECH

PWA  

 

SHUTOFF VALVE

FAILED

4/29/2004

C90A

PT6A21

 

1013890253

FUEL SYSTEM

(CAN) DURING PILOTS PREFLIGHT CHECK THE RT FUEL SHUTOFF VALVE FAILED. THE VALVE WAS REPLACED. TSO 75.4 HOURS

CA040624006

BEECH

LYC  

 

MOTOR

FAILED

6/23/2004

D95A

IO360B1B

 

583800901

MLG 

(CAN) UPON REPLACEMENT, TESTING OF LANDING GEAR MOTOR RECEIVED FROM AN APPROVED OH FACILITY IT WAS DETERMINED MOTOR WAS SPINNING IN REVERSE DIRECTION. MOTOR WAS REMOVED AND BENCH TESTED TO ELIMINATE AN AC WIRING PROBLEM. MOTOR ROTATED IN WRONG DIRECTION AGAIN DURING BENCH TEST AS WELL. MAJOR DAMAGE TO LANDING GEAR COMPONENTS CAN OCCUR DUE TO REVERSE OPERATION OF THIS MOTOR. DUE TO PROPER TESTING BY MAINT MOTOR WAS NOT ALLOWED TO RUN LONG ENEOUGH TO CAUSE ANY DAMAGE TO THE LANDING GEAR COMPONENTS. THE OVERHAUL FACILITY WAS CONTACTED AND ADVISED OF THE PROBLEM AND WERE HELPFUL IN DETERMINING THE PROBABLE CAUSE OF THE MOTOR MALFUNCTION. THE MOTOR HAS BEEN RETURNED TO OVERHAUL FACILITY FOR TESTING AND REPAIR.

AUS20040181

BEECH

CONT

 

SCREW

WRONG PART

3/10/2004

S35  

IO520B

 

 

FUSELAGE FLOOR

(AUS) ELEVATOR CONTROL CABLE RUBBING ON SCREW. INVESTIGATION FOUND (A LONGER THAN NORMAL) SCREW HOLDING THE FORWARD CABIN FLOOR IN POSITION. INCORRECT SCREW HAD BEEN FITTED DURING REUPHOLSTERING CARRIED OUT APPROXIMATELY TWO WEEKS PREVIOUSLY. UNAPPROVED PART. PERSONNEL/MAINTENANCE ERROR.

CA040708012

BELL  

ALLSN

 

DRAIN VALVE

LEAKING

7/5/2004

206B

250C20

 

222366621

FUEL SYSTEM

(CAN) DURING MAINTENANCE GROUND RUN IAW MM-1-5/27, THE ENGINE FLAMED OUT WHEN THE BOOST PUMPS WERE SHUT OFF. THIS FAILURE WAS REPEATABLE. TROUBLE SHOOTING REVEALED AIR ENTERING THE FUEL SYSTEM THROUGH THE AIRFRAME FUEL FILTER ASSEMBLY DRAIN VALVE. THE AIRFRAME FUEL FILTER ASSEMBLY P/N 222-366-621-001 WAS REPLACED WITH P/N 222-366-621-003 AND THE AIRCRAFT WAS RUN IAW MM-1-5/27. THE PROBLEM WAS RECTIFIED. THE DEFECTIVE PART TRACEABILITY IS BEING REVIEWED.

AUS20040362

BELL  

ALLSN

BELL  

GEAR

WORN

4/6/2004

206B

250C20

 

206040662101

M/R GEARBOX

(AUS) MAIN TRANSMISSION SUN GEAR PN 206-040-662-101 AND SUN GEAR SHAFT PN 206-040-040-005 WORN BEYOND LIMITS IN SPLINED AREAS. INVESTIGATION FOUND THE SUN GEAR UPPER O RING PN M83248/1-228 WAS TORN AND SLICED IN SEVERAL AREAS AND THE SUN GEAR LOWER O-RING PN M83248/1-232 WAS ILL FITTING AND COULD BE REMOVED WITH LITTLE EFFORT. SUSPECT WEAR WAS CAUSED BY CONTAMINATION OF THE SUN GEAR SPLINE LUBRICATION GREASE BEING CONTAMINATED WITH TRANSMISSION LUBRICATING OIL DUE TO DAMAGED AND ILL FITTING O-RINGS.

CA040604015

BELL  

ALLSN

 

PIN  

DISLODGED

6/4/2004

206B

250C20B

 

206010795105

T/R PITCH

(CAN) PIN P/N 100-035-187.5-30.5 WAS INSTALLED CORRECTLY. HOWEVER AN ADDITIONAL PIN WAS FOUND FLOATING INSIDE THE SHAFT. THE LAST MAINTENANCE PERFORMED IN THAT AREA WAS 27 JUNE 2003. APPROX 666.1 HOURS. PIN WAS REMOVED AND THE REST OF THE ASSEMBLY WAS INSPECTED FOR DAMAGE. AIRCRAFT RETURNED TO SERVICE AFTER ACCEPTABLE TEST FLIGHT.

CA040419001

BELL  

ALLSN

 

COMPRESSOR

DAMAGED

4/16/2004

206L

250C20R

 

23050833

ENGINE

(CAN) ENGINE FAIL AT APPROX 150 FT. AGL ON CLIMB OUT, PILOT HEARD LOUD BANG ENGINE QUIT. PRELIMINARY INSPECTION SHOWS COMPLETE COMPRESSOR FAILURE.

CA040623009

BELL  

ALLSN

 

BLADE

PERFORATED

6/23/2004

206L

250C20R2

 

206016201131

TAIL ROTOR

(CAN) WHILE CARRYING OUT REQUIREMENTS OF AD CF-2004-05(BHTC ASB 206L-04-127 REV A) A PIN HOLE IN THE EPOXY FILLER, APPROXIMATELY .012 IN. DIA, INTRUDING INTERNALLY, WAS FOUND. WATER WAS OBSERVED DRAINING FROM THE HOLE. BLADE HAS BEEN SCRAPPED. WARRANTY CLAIM SUBMITTED.

CA040603007

BELL  

ALLSN

 

TURBINE

LOCKED

6/2/2004

206L

250C20R2

 

 

ENGINE

(CAN) TURBINE HAD AN N2 LOCK UP. SUSPECT UNKNOWN AT THIS TIME. TURBINE SENT TO OVERHAUL SHOP FOR ASSESSMENT.

CA040624005

BELL  

ALLSN

 

FITTING

CRACKED

5/24/2004

206L1

250C28B

 

206030329103

TAILBOOM

(CAN) FORWARD UPPER LT TAILBOOM ATTACHMENT FITTING FOUND CRACKED DURING 200 HOUR INSPECTION. MFG INSPECTION CALLS FOR SPECIAL ATTENTION TO THIS AREA DURING THE INSPECTION. THIS IS A KNOWN PROBLEM AREA.

AUS20040386

BELL  

ALLSN

BELL  

GEAR

FAILED

5/4/2004

206L1

250C30

 

2060400209

M/R GEARBOX

(AUS) MAIN ROTOR TRANSMISSION INPUT PINION GEAR FAILED. GEAR TEETH STARTING TO BREAK DOWN WITH DISTINCT WEAR PATTERN AND PITTING ON THE FLANK OF ALL GEAR TEETH AND ADVANCED BREAKING DOWN OF SOME OF THE TEETH. METAL CONTAMINATION OF TRANSMISSION.

AUS20040440

BELL  

ALLSN

 

STIFFENER

CRACKED

5/26/2004

206L3

250C30

 

206033201167

ENGINE MOUNT

(AUS) RT FORWARD ENGINE MOUNT STIFFENER CRACKED THROUGH. CRACK MIGRATED INTO LATERAL FRAME AT STN 155.

CA040420004

BELL  

ALLSN

 

ANGLE

CRACKED

4/1/2004

206L3

250C30P

 

206032307

FUSELAGE

(CAN) A CRACK WAS FOUND IN A 1200 HR INSPECTION. THE PART WAS REPLACED AND TB 206L-87-139 WAS C/W TO STOP MORE DAMAGE

CA040420005

BELL  

ALLSN

 

TURBINE

CRACKED

4/13/2004

206L3

250C30P

 

23033195

1ST STAGE NOZZLE

(CAN) WHEN INSTALLING A NEW SMOKELESS LINER A CRACK WAS WAS FOUND IN FIRST NOZZLE. TURBINE WAS REPAIRED AT AN ENGINE SHOP

CA040526004

BELL  

ALLSN

BELL  

CASE

CORRODED

5/20/2004

206L4

250C30

 

406040056107

M/R GEARBOX

(CAN) A DOZEN STUD HOLES FOUND DEEPLY CORRODED AND NEEDED SPECIAL REPAIR IAW MFG INSTRUCTIONS. THE CORROSION IS CAUSED BY DISSIMILAR METALS AND MOISTURE. MFG CANNOT SOLVE THE PROBLEM DEFINITELY BUT SUGGEST METHODS TO SLOW IT DOWN AND DIMINISH DAMAGE TO CASE.

CA040413005

BELL  

PWA  

 

TURBINE WHEEL

DAMAGED

9/6/2003

212  

PT6T3

 

 

NR 2 ENGINE

(CAN) WHEN THROTTLES WERE ROLLED TO IDLE FOR COOL DOWN A LOW GROWL WAS HEARD AT IDLE. ENGINES WERE SPUN UP TO 100 PERCENT AND GROWL WENT AWAY. BOTH ENGINES WERE BROUGHT BACK TO IDLE AND NOISE WAS HEARD AGAIN. ENGINES WERE SPOOLED UP SEPARATELY AND PROBLEM WAS ISOLATED TO NR 2 ENGINE. ENGINEER WAS NOTIFIED. DURING BOROSCOPE INSPECTION OF NR 2 ENGINE IT WAS DISCOVERED THAT PORTIONS OF 7 BLADES WERE MISSING. POWER SECTION REMOVED DUE TO CT WHEEL DISTRESS.

CA040413006

BELL  

ALLSN

 

BLADE

CONTAMINATED

3/25/2004

407  

250C47B

 

406016100119

TAIL ROTOR

(CAN) ONE TAILROTOR BLADE FOUND TO HAVE ABSORBED WATER, THROWING THE TAILROTOR OUT OF BALANCE AND CREATING EXCESSIVE VIBRATIONS.

CA040604004

BELL  

ALLSN

LUCAS

BEARING

ROUGH

6/2/2004

407  

250C47B

 

PW203PPC7FS500

STARTER GEN

(CAN) STARTER-GEN, UNDERGOING IMPORT INSPECTION. BEARINGS WERE FOUND TO BE ROUGH AND NOISY WHEN SPUN. REMOVED BEARINGS, FOUND THEM TO BE SUP. ARE MARKED PW203PP C7 FS50000. IAW DATAPLATE, THEY SHOULD BE P/N 03-6009-23 (MOD B). THE SOURCE OF THE LAST OVERHAUL IN MAY 2002 IS KNOWN. PHOTO OF BEARINGS IS APPENDED.

AUS20040411

BELL  

LYC  

 

BRACKET

MISSING

4/5/2004

47G3B1

TVO435B1A

 

476221651

TAIL ROTOR

(AUS) DUAL TAIL ROTOR CONTROL PEDAL SYSTEM INTERFERENCE BRACKET NOT FITTED. AD/BELL47/69 REQUIRES THE BRACKET TO BE FITTED TO DUALCONTROL BELL/AGUSTA 47 SERIES AIRCRAFT. THE BRACKET PREVENTS INCORRECT FITMENT OF THE DUAL PEDAL CONTROLS. PERSONNEL/MAINTENANCE ERROR.

CA040414004

BNORM

LYC  

 

BEARING

DESTROYED

4/6/2004

BN2  

O540E4C5

 

13889

MLG WHEEL

(CAN) NR 4 WHEEL OUTER AND INNER BEARINGS FAILED. THE BRAKE CALIPER SLIPPED FROM THE TORQUE PLATE AND THE BRAKE HYDRAULIC HOSE BROKE. THE CAPTAIN USED THE AIRCRAFT FIRE EXTINGUISHER TO EXTINGUISH THE SMOKE AT THE WHEEL. SHE SAYS NO FIRE WAS SEEN. THE AXLE WAS FOUND DAMAGED DUE TO THE FAILED WHEEL BEARINGS.

AUS20040320

BNORM

LYC  

WOODWARD

SHAFT

SHEARED

4/27/2004

BN2A26

O540E4C5

 

923309D

PROP GOVERNOR

(AUS) RT ENGINE PROPELLER GOVERNOR DRIVESHAFT SHEARED IN AREA LEVEL WITH THE MOUNTING FACE.

CA040317002

BNORM

LYC  

 

BRAKE DISC

CRACKED

3/10/2004

BN2B27

O540E4C5

 

16402201

MLG 

(CAN) DISC FAILED AROUND FLANGE. PART 6 OF SB 7071 ASK PILOTS TO LOOK AT WHEELS DISC ON PRE-FLIGHT INSPECTION, AT THE STAGE OF THE CRACK NOW IT WOULD HAVE BEEN NEXT TO IMPOSSIBLE TO SEE THE CRACK WITHOUT CLEANING THE DISC.

CA040329001

BOEING

PWA  

 

SELECTOR PANEL

FAILED

3/27/2004

727223

JT8D15A

 

G2412

VHF COMMS

(CAN) DURING DESCENT, COMMUNICATIONS WERE LOST. AN EMERGENCY WAS DECLARED AND THE AIRCRAFT LANDED WITHOUT INCIDENT. THE FIRST OFFICER'S AUDIO SELECTOR PANEL WAS SUSPECT. A HOT MIKE SITUATION WAS APPARENT IN VHF 1 AND VHF 2. THE AUDIO SELECTOR PANEL WAS REPLACED IAW MM 23-20-00 AND CHECKED SERVICEABLE. NO FURTHER INCIDENT DURING SUBSEQUENT FLIGHT.

CA040624008

BOEING

PWA  

 

ENGINE

MALFUNCTIONED

6/22/2004

727225

JT8D15A

 

 

 

(CAN) DURING TAKE-OFF, THE CREW REPORT THAT THEY HAD HEARD A BANG. ALL ENGINE PARAMETERS WERE NORMAL. THE AIRCRAFT MADE AN UNSCHEDULED LANDING. ALL ENGINES WERE PHYSICALLY INSPECTED WITH NO APPARENT DAMAGE. ALL 3 ENGINES WERE STARTED, POWERED UP AND REVERSERS DEPLOYED. ALL ENGINES WERE CHECKED SERVICEABLE IAW MM 71-00 AND PWA MM 71-00-00. THE AIRCRAFT WAS RELEASED AND NO FURTHER INCIDENT DURING SUBSEQUENT FLIGHT.

CA040713011

BOEING

PWA  

 

SWITCH

FAILED

7/13/2004

727225

JT8D9A

 

1EN161RB1

MLG 

(CAN) AFTER TAKEOFF WHEN THE GEAR WAS RETRACTED, THE LEFT MAIN GEAR DOOR LIGHT ON THE ENGINEERS PANEL AND THE DOOR UNSAFE LIGHT REMAINED ILLUMINATED. THE CREW CYCLED THE GEAR AND THE LIGHT REMAINED ON, THE CREW ELECTED TO RETURN TO THE POINT OF ORIGIN. THE SWITCH AND CONNECTOR WERE REPLACED AND THE AIRCRAFT DEPARTED.

CA040415005

BOEING

PWA  

 

ATTACH FITTING

CRACKED

4/5/2004

727227

JT8D9A

 

6524480412

MLG UPLOCK

(CAN) DURING ROUTINE MAINTENANCE BY VISUAL INSPECTION OF THE RT LANDING GEAR UPLOCK ATTACH FITTING, A SUSPECTED CRACK WAS DETECTED AT THE UPLOCK ATTACH LUG. FITTING WAS REMOVED FROM AIRCRAFT AND SUBMITTED FOR NDT. NDT INSPECTION BY EDDY CURRENT CARRIED OUT AND CONFIRMED THAT THE LUG WAS CRACKED TO APPROXIMATELY 50 PERCENT OF MATERIAL. FITTING REPLACED ON AIRCRAFT.

CA040325002

BOEING

PWA  

 

ACTUATOR

LEAKING

3/25/2004

72722C

JT8D7B

 

269002916

LE FLAP

(CAN) ON APPROACH INTO CYVR SELECTED FLAPS 2, AMBER IN-TRANSIT LIGHT STAYED ON. NR 7 SLAT DID NOT EXTEND. HYDRAULIC SYSTEM (A) LOW PRESSURE LIGHTS ILLUMINATED AND HYDRAULIC (A) SYSTEM QUANTITY INDICATED ZERO QUANTITY. AIRCRAFT WAS VECTORED AND CREW PERFORMED HYDRAULIC LOSS CHECK LIST AND ONE SLAT INOP. LANDING CHECK LIST. AFTER CHECK LISTS COMPLETED AN EMERGENCY WAS DECLARED AND THE AIRCRAFT LANDED AND WAS TOWED TO THE RAMP. NR 7 SLAT ACTUATOR END CAP THREADS FAILED CAUSING A LEAK AND LOSS OF HYDRAULIC FLUID.

CA040521001

BOEING

PWA  

 

MODULE

FAILED

5/19/2004

727243

JT8D15

 

656021123

MLG ACTUATOR

(CAN) ON CLIMB OUT, CREW NOTICED NOSE (GEAR UNSAFE) LIGHT DID NOT EXTINGUISH. AFTER DUMPING FUEL, CREW RETURNED TO MAINTENANCE FACILLITY WHERE THE LANDING GEAR ACCY UNIT WAS REPLACED AND GEAR SWINGS PERFORMED. A/C RETURNED TO SERVICE.

CA040625002

BOEING

PWA  

 

FIRE LOOP

MALFUNCTIONED

6/24/2004

727260

JT8D17

 

 

NR 3 ENGINE

(CAN) DURING FLIGHT, NR 3 ENGINE FIRE WARNING INDICATION WAS ACTIVATED. BELL WAS INTERMITTENT BUT BECAME A LITTLE MORE STEADY. EMERGENCY PROCEDURES WERE INITIATED AND NR 3 ENGINE WAS SHUTDOWN. FIRE HANDLE WAS PULLED BUT NOT TO RELEASE EXTINGUISHING AGENT. ATC WAS NOTIFIED. AIRCRAFT LANDED WITHOUT INCIDENT WITH EMERGENCY VEHICLES ON SITE. AIRCRAFT WAS SHUTDOWN. MTCE ACCESSED THE SITUATION. AN ELECTRICAL SHORT WAS FOUND IN THE NR 3 ENGINE FIRE LOOP SYSTEM. THE AIRCRAFT WAS RUN UP WITH NO FURTHER PROBLEMS. THE AIRCRAFT WAS RELEASED. NO FAULT DURING SUBSEQUENT FLIGHT.

CA040625005

BOEING

PWA  

 

MODULATING VALVE

LEAKING

6/22/2004

727260

JT8D17

 

39271611

NR 1 BLEED SYS

(CAN) DURING CLIMB IT WAS OBSERVED THAT THE NR 1 ENGINE STRUT OVERHEAT LIGHT CAME ON. IAW OPS CHECKLIST, SYSTEM CHECK CARRIED OUT AND FLIGHT CONTINUED WITHOUT INCIDENT. AFTER LANDING, INSPECTION WAS CARRIED OUT AND THE HIGH PRESSURE MODULATING AND SHUTOFF VALVE WAS FOUND LEAKING. THE VALVE WAS REPLACED. LEAK CHECK CARRIED OUT AND CHECKED SERVICEABLE IAW MM 26-12-41.

CA040625006

BOEING

PWA  

 

SHUTOFF VALVE

LEAKING

6/24/2004

727260

JT8D17

 

600231

13TH STAGE DUCT

(CAN) DURING CLIMB NR 1 ENGINE STRUT OVERHEAT LIGHT ILLUMINATED. OPS CHECKLIST CARRIED OUT. AIRCRAFT WAS RETURNED TO BASE DUE TO SECOND INCIDENT IN 2 DAYS. DURING INSPECTION, NR 1 ANTI ICE VALVE SEALS WERE REPLACED. NR 1 BLEED SHUT OFF VALVE WAS REPLACED IAW MM 36-10-01. HIGH POWER RUNS WERE CARRIED OUT. NO LEAKS FOUND AND NR 1 ENGINE STRUT OVERHEAT LIGHT DID NOT ILLUMINATE AFTER THE 15 MINUTE RUN. NO FURTHER PROBLEM DURING SUBSEQUENT FLIGHT.

AUS20040438

BOEING

PWA  

 

DOOR FRAME

CRACKED

5/13/2004

727277

JT8D15

 

65561001

FUSELAGE

(AUS) NR 1 CARGO DOOR FRAME CRACKED IN AREAS ADJACENT TO DOOR STOP NR 5 AND NR 6. FOUND DURING INSPECTION IAW AD/B727/165 AND MFG SB727-53A0219.

AUS20040376

BOEING

PWA  

 

BEARING

SEIZED

4/28/2004

727277

JT8D15

 

 

TE FLAPS

(AUS) IB FLAP SELECTOR VALVE INPUT ROD SELF ALIGNING BEARING BINDING DUE TO LACK OF LUBRICATION.

CA040520002

BOEING

PWA  

 

CONTROL CABLE

BROKEN

5/15/2004

72744C

JT8D7B

 

BACC2A3A01262GG

SPOILERS

(CAN) MAINTENANCE FOUND THE WSB2 CABLE BROKEN WHEN INVESTIGATING A REPORT OF SPOILER FLOAT. THE CABLE WAS REPLACED AND THE AIRCRAFT RETURNED TO SERVICE.

CA040415001

BOEING

CFMINT

 

MOTOR

FAILED

3/27/2004

737*

CFM567B22

 

6355C000101

STAB TRIM

(CAN) FLIGHT CREW REPORTS WHILE AT LEVEL AT FLIGHT 39,000 FT, (AUTOPILOT DISENGAGED, MASTER CAUTION FLIGHT CONTROL ILLUMINATED, SPEED TRIM FAIL LIGHT ILLUMINATED, NO ELECTRIC TRIM, NO AUTOPILOT) FOLLOWING IN-FLIGHT TROUBLESHOOTING/NON NORMAL CHECKLISTS, AC LANDED W/O INCIDENT. MAINT REPLACED ELECTRIC STABILIZER TRIM MOTOR IAW MM AND TESTED SYSTEM IAW MM. NO FAULTS FOUND. AC RETURNED TO SERVICE WITH NO FURTHER PROBLEMS TO REPORT. THIS UNIT IS A NEW MFG (C) MODEL WHICH VENDOR HAS COMPLETELY OVERHAULED BECAUSE OF PROBLEMS WITH THEIR (B) MODEL. THIS WAS FIRST SUCH STAB TRIM PROBLEM WITH NEW (C) MODEL AND IS CURRENTLY BEING INVESTIGATED BY MFG. RELIABILITY DEPT IS CURRENTLY WAITING FOR FINAL STRIP REPORT FROM MFG.

AUS20040331

BOEING

GE  

 

LINE

LOOSE

4/26/2004

737*

CFM567B24

 

 

SPOILER ACTUATOR

(AUS) OB SLAT ACTUATOR HYDRAULIC LINE LOOSE AND LEAKING.

AUS20040439

BOEING

GE  

 

TIRE

SEPARATED

5/26/2004

737*

CFM567B24

 

277A6000204

MLG 

(AUS) NR 2 MAIN WHEEL TIRE TREAD SEPARATED AND TIRE DEFLATED.

AUS20040430

BOEING

GE  

 

BOLT

MISSING

5/21/2004

737*

CFM567B24

 

AS323710

AC GENERATOR

(AUS) INTEGRATED DRIVE GENERATOR (IDG) OIL/AIR COOLER BOLTS (5 OFF) MISSING AND REMAINING BOLTS (3 OFF) LOOSE. TWO BOLTS AND WASHERS WERE FOUND IN THE COWL.

AUS20040389

BOEING

GE  

 

TERMINAL

FAULTY

5/11/2004

737*

CFM567B24

 

TB262XA3

RUDDER CONTROL

(AUS) STANDBY RUDDER SHUTOFF VALVE WILL NOT CLOSE ON SELECTION. INVESTIGATION FOUND WIRES W2212-0521-20 AND W5170-0505-20 TOTB262-XA3 NOT LOCKED INTO POSITION CAUSING OPEN CIRCUIT.

CA040505005

BOEING

PWA  

 

HOSE

FAILED

5/3/2004

737201

JT8D9A

 

BACH8B04NN214T

NLG 

(CAN) ON DEPARTURE THE NOSE GEAR FAILED TO RETRACT WHEN THE LANDING GEAR SELECTOR WAS MOVED TO THE UP POSITION. RETURNED TO BLOCKS. HOSE REPLACED WITH LOANER HOSE.

CA040412013

BOEING

PWA  

 

WHEEL

BROKEN

4/9/2004

737201

JT8D9A

 

26010452

NLG 

(CAN) DURING AIRCRAFT LOW SPEED TAXI TO RUNWAY, THE INBOARD WHEEL HALF OF THE RT NOSEWHEEL ASSEMBLY SEVERED AND TIRE DEFLATED. FUSELAGE AND NLG AREA INSPECTED FOR DAMAGE. NO FAULTS FOUND. BOTH NOSE LANDING GEAR WHEEL ASSEMBLIES REPLACED IAW MM.

CA040413009

BOEING

PWA  

 

DRAG BRACE

CRACKED

4/10/2004

737201

JT8D9A

 

658005113

NLG 

(CAN) NOSE GEAR UPPER DRAG BRACE HAS A CRACK APPROXIMATELY .2500 INCHES IN LENGTH AND .1250 INCHES IN DEPTH, NEAR LT GEAR DOOR ATTACHMENT POINT. UPPER DRAG BRACE REPLACED.

CA040413010

BOEING

PWA  

 

DRAG BRACE

CRACKED

4/9/2004

737201

JT8D9A

 

658005113

NLG 

(CAN) NOSE GEAR UPPER DRAG BRACE HAS A CRACK APPROXIMATELY .2500 INCHES IN LENGTH AND .1250 INCHES IN DEPTH, NEAR LT GEAR DOOR ATTACHMENT POINT. UPPER DRAG BRACE REPLACED. TIMES 57213:23 CYCLES 53614.

CA040625003

BOEING

PWA  

 

CASTING

CRACKED

6/24/2004

737201

JT8D9A

 

 

VERTICAL STAB

(CAN) DURING MAINTENANCE CHECK A CRACK WAS FOUND ON THE SPIDER CASTING AT RUDDER STATION 23.27 BELOW THE STANDBY RUDDER PCU IN THE VERTICAL STABILIZER. THE CRACK IS 3 INCHES IB OF OUTER EXTREMITIES, 7 INCHES FORWARD OF THE LOWER RUDDER HINGE POINT APPROX 1.5 INCHES LONG AND .6250 INCHES FROM THE BASE. CRACK REPAIRED WITH AN EXTRUSION ANGLE IAW INSTRUCTIONS FROM MFG MESSAGE 1-31239593. TIMES, 61592.12 CYCLES 59677.

CA040625004

BOEING

PWA  

 

ACTUATOR

INOPERATIVE

6/24/2004

737217

JT8D17

 

 

SLAT 

(CAN) NR 6 LEADING EDGE SLAT WAS SLOW TO RETRACT ON DEPARTURE. AFTER IT DID RETRACT IT RE-EXTENDED FOR ABOUT 5 MINUTES THEN RETRACTED AGAIN. CREW WAS ALERTED BY SLAT INDICATION OF THE REDEPLOYMENT AND VISUALLY CONFIRMED THE EXTENSION AND RETRACTION. NO OTHER ACTION TAKEN AND THE CREW CONTINUED TO DESTINATION. MAINTENANCE REPLACED THE NR 6 SLAT ACTUATOR AND THE AIRCRAFT WAS RELEASED FOR SERVICE. ACTUATOR SENT TO SHOP FOR EVALUATION AND A FULL REPORT HAS BEEN REQUESTED. THE PART IS IN TRANSIT, WILL UPDATE WITH THE ACTUATOR PN AND SN.

CA040519014

BOEING

PWA  

 

ACTUATOR

FAILED

5/18/2004

737217

JT8D17

 

65449617

SPOILER

(CAN) DURING TAXI TO GATE LOSS OF NOSE WHEEL STEERING OCCURRED WITH TOTAL LOSS OF HYDRAULIC A PRESSURE AND QUANTITY AT ZERO. MAINTENANCE FOUND THE NR 8 GROUND SPOILER ACTUATOR TO BE THE CAUSE. THE ACTUATOR BODY HAD STRUCTURAL FAILURE CAUSING FLUID LOSS. ACTUATOR REPLACED AND AIRCRAFT RETURNED TO SERVICE. ACTUATOR ROUTED TO OUR MAINTENANCE PROVIDER'S SHOP WITH REQUEST FOR FULL REPORT. WILL ADD FURTHER DETAILS OF THE FAILURE WHEN AVAILABLE.

CA040715005

BOEING

PWA  

 

CONNECTOR

CONTAMINATED

7/14/2004

7372H4

JT8D9A

 

 

NR 2 ENGINE

(CAN) AC RETURNED BECAUSE OF A NR 2 ENG OVERHEAT LIGHT ILLUMINATING AT 23,000 FT. AND WOULD NOT EXTINGUISH. ENG WAS SHUTDOWN IN FLIGHT IAW QRC AND LANDED WITH INCIDENT, CFR FOLLOWED AC TO THE GATE. AFTER TAXIING TO GATE, NR 3 AND NR 4 MAIN WHEEL FUSE PLUGS LET LOOSE. BOTH MAIN WHEELS REPLACED. ON ENGINE OVERHEAT SYSTEM, MAINT FOUND OIL CONTAMINATION IN ONE OF THE ENGINE CONNECTORS. MAINT CLEANED CONNECTORS AND OTHER THAN THAT COULD NOT FAULT SYSTEM. MAINT REPLACED FIRE DETECTION UNIT FOR TROUBLESHOOTING PURPOSES. AC GROUND CHECKS SERVICEABLE AND IS BEING POSITIONED THIS AFTERNOON FOR SCHEDULES FLIGHT PLAN. WILL KEEP AN EYE ON THIS ONE AND ADVISE OF ANY FURTHER DEVELOPMENT SHOULD THEY RE-OCCUR.

CA040419002

BOEING

PWA  

 

CONTROL CABLE

CHAFED

4/13/2004

7372Q9

JT8D9A

 

BACC2A3A00764CG

THRUST REVERSER

(CAN) DURING 'C' CHECK, THE LT ENGINE THRUST LEVER CONTROL CABLE(T1A) WAS FOUND TO BE CHAFED AND HAD BROKEN CABLE STRANDS. DURING INSTALLATION OF NEW CABLE, IT WAS FOUND THAT THE T1A CABLE HAD BEEN ROUTED UNDER THE CABLE GUARD INSTEAD OF OVER, CONTRIBUTING TO THE ABOVE MENTIONED DAMAGE TO THE THRUST LEVER CONTROL CABLE. TIMES 60322.07 CYCLES 56643.

CA040628003

BOEING

PWA  

 

DUCT

CRACKED

6/24/2004

7372T2

JT8D17

 

69432851

GENERATOR COOL

(CAN) ATA 75SDR REPORT: FLIGHT CREW FELT A TRANSIENT VIBRATION ON ENGINE SPOOL-UP, WITH NO INDICATION FROM EITHER ENGINE VIBRATION METER. ALSO SLIGHT VIBRATION IN CRUISE, WITH NO INDICATION ON EITHER ENGINE VIBRATION INDICATOR. FLIGHT CREW ISOLATED THE PROBLEM TO NR 2 ENGINE. AC WAS SWAPPED AFTER MAINT DISCOVERED THAT AC GENERATOR COOLING DUCT PLATE WAS BROKEN AND CAUSING A LARGE COOLING AIR LEAK. PLATE WAS REPLACED AND GROUND RUNS CONFIRM NO VIBRATION. OPERATOR WILL ISSUE A FLEET CAMPAIGN TO INSPECT AC GENERATOR COOLING DUCT PLATES OF REMAINING AIRCRAFT. THIS FLEET CAMPAIGN WILL BE COMPLETED WITHIN 60 DAYS. THE FOLLOWING IS AN EXACT FROM THE IPC. ITEM NR 170 PN 69-43285-1 IS THE PART WHICH FAILED.

AUS20040330

BOEING

GE  

 

FORCE LIMITER

FAULTY

5/2/2004

737376

CFM563B1

 

R1053M182

AUTOPILOT SYSTEM

(AUS) AUTOPILOT WOULD NOT ENGAGE. SUSPECT FAULTY FORCE LIMITER.

AUS20040384

BOEING

GE  

 

INDICATOR

FAULTY

4/26/2004

737376

CFM563B1

 

2061141

TE FLAPS

(AUS) FLAP POSITION INDICATOR FAULTY.

AUS20040388

BOEING

GE  

 

GENERATOR

FAILED

5/9/2004

737376

CFM563B1

 

 

APU 

(AUS) APU GENERATOR FAILED.

AUS20040415

BOEING

GE  

 

DRIVE SHAFT

WORN

5/13/2004

737376

CFM563B1

 

65503245

TE FLAP DRIVE  

(AUS) NR 4 TRAILING EDGE FLAP TRANSMISSION UNIVERSAL DRIVESHAFT WORN AXIALLY BEYOND LIMITS. END FLOAT WAS APPROXIMATELY 0.406MM(0.016IN) AT OUTPUT END.

AUS20040426

BOEING

GE  

 

WINDSHIELD

FAILED

5/18/2004

737376

CFM563B1

 

 

COCKPIT

(AUS) FIRST OFFICER'S NR 1 WINDOW OUTER PANE SHATTERED ALONG WITH ARCING FROM THE WINDSCREEN.

AUS20040422

BOEING

GE  

 

TIRE

DAMAGED

5/14/2004

737376

CFM563B1

 

 

NLG 

(AUS) RT NOSE LANDING GEAR TIRE DAMAGED BY DEBRIS ON RUNWAY. TIRE SHREDDED AND CAUSED DAMAGE TO FORWARD LOWER FUSELAGE SKIN. FOD WAS IDENTIFIED AS THRUST REVERSER BLOCKER DOOR PARTS.

AUS20040423

BOEING

GE  

 

AUTOPILOT SYS

FAILED

5/17/2004

737376

CFM563B1

 

 

COCKPIT

(AUS) DUAL AUTOPILOT MALFUNCTION. LIMITED INFORMATION PROVIDED.

AUS20040365

BOEING

GE  

 

OVEN

FAULTY

5/6/2004

737376

CFM563B1

 

GENM2585015

GALLEY

(AUS) AFT GALLEY OVEN ELECTRICAL FAULT. INVESTIGATION FOUND FILTERBOARD CAUGHT FIRE DUE TO THE FORMATION OF DRY SOLDER JOINTS ON INDUCTOR CONTACTS.

AUS20040340

BOEING

CFMINT

 

SEAL

LEAKING

4/26/2004

737400

CFM563C

 

B1773

CSD 

(AUS) NR 2 CONSTANT SPEED DRIVE (CSD) GENERATOR DRIVE SEAL WORN AND LEAKING.

AUS20040367

BOEING

CFMINT

 

SLIDE

FAILED

5/3/2004

737476

CFM563C

 

737M25651017

L2 DOOR

(AUS) DOOR 2L ESCAPE SLIDE LIGHTS FAILED TO ILLUMINATE FOLLOWING SLIDED EMPLOYMENT. SUSPECT FLAT BATTERY.

AUS20040427

BOEING

CFMINT

 

PANEL

FAULTY

5/20/2004

737476

CFM563C

 

 

MLG INDICATOR

(AUS) LANDING GEAR POSITION PANEL FAULTY.

AUS20040387

BOEING

CFMINT

 

CONTROL COLUMN

BINDING

4/29/2004

737476

CFM563C

 

 

COCKPIT

(AUS) FIRST OFFICER'S CONTROL COLUMN ELL FITTING CHAFING ON TRANSFER MECHANISM FORK. TRANSFER MECHANISM WAS FOUND TO HAVE A PRESERVICE BULLETIN FORK FITTED INSTEAD OF A POST SERVICE BULLETIN FORK.

AUS20040394

BOEING

CFMINT

 

SPAR

CRACKED

5/6/2004

737476

CFM563C

 

 

HORIZONTAL STAB

(AUS) HORIZONTAL STABILIZER REAR SPAR SUSPECT CRACKED. EDDY CURRENT INSPECTION CONFIRMED THE FOLLOWING CRACKS. STABILIZER REAR SPAR RT FORWARD FACE OF TOP WEB ASSEMBLY. CRACK INDICATION CONFIRMED. CRACK LENGTH 10.16MM (0.400IN)OUT OF FASTENER HOLE. HORIZONTAL STABILIZER CENTER SECTION REAR SPAR RT HOLE. EDDY CURRENT INSPECTION CARRIED OUT. WEB CRACKED 6 O’CLOCK POSITION.

CA040715001

BOEING

CFMINT

 

DISPLAY

SMOKE

7/13/2004

73776N

CFM567B22

 

50401100003

ENTERTAIN SYS

(CAN) FLT UPON ARRIVAL, GUEST INFORMED FLIGHT CREW SMOKE WAS COMING FROM THE (LIVE TV) VIDEO DISPLAY UNIT (TV SCREEN). CAPTAIN IMMEDIATELY TURNED OFF POWER TO SYSTEM AND AIRCRAFT PROCEEDED TO GATE AND DEPLANED GUESTS. LIVE TV TECHNICIAN, TRAVELING ONBOARD AIRCRAFT AS PART OF INITIAL INSTALLATION SUPPORT PROGRAM REPLACE DVDU SCREEN FROM SEAT BACK IAW LTV-AMM-23-32-03 AND ISSUED MEL 25-10-5.AIRCRAFT RETURNED TO SERVICE WITH NO FURTHER INCIDENTS TO REPORT. DURING RON THAT EVENING, LIVE TV TECHNICIAN COMPLETED LIVE TV 1ST LEVEL OPERATIONAL CHECK IAW LIVE TV AMM-23-32-03 -SYSTEM CHECKED SERVICEABLE. VDU RE-CONNECTED, MEL CLEARED AND AIRCRAFT RETURNED TO SERVICE WITH NO FURTHER INCIDENTS TO REPORT.

AUS20040335

BOEING

GE  

 

IDG  

FAULTY

5/1/2004

73776N

CFM567B24

 

 

AC GENERATOR

(AUS) NR 2 INTEGRATED DRIVE GENERATOR (IDG) SUSPECT FAULTY.

AUS20040397

BOEING

GE  

 

SEPARATOR

CONTAMINATED

5/10/2004

7377Q8

CFM567B24

 

213A10031

CABIN COOLING SY

(AUS) AIR CONDITIONING SYSTEM DUCTING, WATER SEPARATORS AND COALESCER BAGS CONTAMINATED WITH OIL. SUSPECT CAUSED BY OVERFILLING OF APU OIL SYSTEM.

AUS20040432

BOEING

GE  

 

NIPPLE

CRACKED

4/30/2004

7377Q8

CFM567B24

 

3401659010

THRUST REVERSER

(AUS) LT THRUST REVERSER OIL SCAVENGE LINE NIPPLE CRACKED.

AUS20040248

BOEING

GE  

 

INSERT

WRONG PART

3/31/2004

737800*

CFM56*

 

8202017

GALLEY

(AUS) INCORRECT OVEN INSERT (TRAYS) USED IN NO4 OVEN. INSERT DID NOTHAVE A HEAT/PROTECTIVE SHIELD FITTED AT THE REAR ALLOWING THE MEAL PACKAGING TO CONTACT HEATING ELEMENTS. UNAPPROVED PART.PERSONNEL/MAINTENANCE ERROR.

AUS20040431

BOEING

GE  

 

PIPE

LOOSE

5/20/2004

737800*

CFM567B24

 

3400140070

TURBINE ENGINE

(AUS) ENGINE NR 4 AND NR 5 BEARING OIL SUPPLY LINE B NUT LOOSE (FINGERTIGHT). LOSS OF ENGINE OIL. PERSONNEL/MAINTENANCE ERROR.

AUS20040424

BOEING

GE  

 

SENSOR

FAULTY

5/25/2004

737800*

CFM567B24

 

0861F1

STALL WARNING SY

(AUS) LT ANGLE OF ATTACK (AOA) SENSOR FAULTY.

AUS20040417

BOEING

GE  

 

BRAKE

FAULTY

5/16/2004

737800*

CFM567B24

 

26123121

RT MLG

(AUS) RT MAIN LANDING GEAR IB BRAKE FAULTY.

AUS20040336

BOEING

GE  

 

FITTING

CRACKED

4/25/2004

737800*

CFM567B24

 

BACC27AC10061006

HYDRAULIC SYSTEM

(AUS) FOUR WAY HYDRAULIC FITTING CRACKED AND LEAKING.

AUS20040328

BOEING

GE  

 

ODOR

DETECTED

5/1/2004

737800*

CFM567B24

 

 

CABIN

(AUS) STRONG BURNING ODOR ON FLIGHT DECK AND IN CABIN. EXTENSIVE INVESTIGATION COULD FIND NO CAUSE FOR THE PROBLEM OR ANY EVIDENCE OF BURNING.

AUS20040353

BOEING

RROYCE

 

WIRE

BROKEN

4/16/2004

747338

RB211524*

 

 

ENGINE

(AUS) ENGINE AIRBORNE VIBRATION MONITOR INDICATION MODULE SELECTOR SWITCH WIRE FROM PIN 19 OF CONNECTOR DM162 BROKEN.

AUS20040443

BOEING

RROYCE

 

INDICATOR

FAULTY

5/19/2004

747338

RB211524D419

 

98010903

TE FLAPS

(AUS) LT OB TRAILING EDGE FLAP INDICATOR FAILED.

AUS20040390

BOEING

RROYCE

 

BOLT

INCORRECT

5/6/2004

747338

RB211524D419

 

 

MLG 

(AUS) LT WING LANDING GEAR TO LANDING GEAR DOOR TIE ROD BOLTS INCORRECTLY FITTED. BOLTS WERE FITTED UPSIDE DOWN. PERSONNEL/MAINTENANCE ERROR.

AUS20040332

BOEING

GE  

 

MOTOR

SEIZED

4/20/2004

747438

CF680C2*

 

413T1001

TE FLAPS

(AUS) OB TRAILING EDGE FLAP ELECTRIC MOTOR SEIZED.

AUS20040418

BOEING

RROYCE

RROYCE

BLOCKER DOOR

SEPARATED

5/15/2004

747438

RB211524*

 

 

THRUST REVERSER

(AUS) NR 1 ENGINE THRUST REVERSER NR 9 BLOCKER DOOR DAMAGED. CONTROL LINKAGE, FITTING AND APPROXIMATELY 40 PERCENT OF THE BLOCKER DOOR MISSING.

AUS20040428

BOEING

RROYCE

 

FAN  

FAULTY

5/12/2004

747438

RB211524G19

 

 

AIR DISTRIBUTION

(AUS) SMOKE AND FUMES IN COCKPIT. SMOKE AND FUMES STOPPED WHEN UPPER FANS SWITCH OFF. CIRCUIT BREAKER TRIPPED.

AUS20040329

BOEING

RROYCE

 

TIRE

DEFLATED

4/8/2004

747438

RB211524G19

 

161U000115

MLG 

(AUS) TIRE DEFLATED DURING FLIGHT.

AUS20040323

BOEING

RROYCE

 

DUCT

LEAKING

4/9/2004

747438

RB211524G19

 

 

APU BLEED AIR

(AUS) BURNING ODOR IN CABIN. SUSPECT CAUSED BY APU BLEED AIR DUCT LEAK.

AUS20040453

BOEING

RROYCE

 

CONTROL CABLE

WORN

5/28/2004

747438

RB211524G19

 

BACC2C4C05138EG

AILERON

(AUS) AILERON CABLE OUTER STRANDS BROKEN IN AREA LOCATED AT RT WING SPAR TRAILING EDGE AT WS 1110. SOME OUTER STRANDS WERE ALSO BROKEN IN AN AREA LOCATED FURTHER OB AT APPROXIMATELY WS 1195. SUSPECT CAUSED BY CABLE WEARING ON FAIRLEADS ALONG THE WING TRAILING EDGE.

AUS20040366

BOEING

RROYCE

 

PANEL

INCORRECT

5/5/2004

747438

RB211524G19

 

 

COCKPIT

(AUS) COCKPIT IB DECORATIVE PANEL FORWARD EDGE OVERLAPPING CAUSING CAPTAINS RUDDER PEDALS TO BIND DURING FULL TRAVEL CONTROL CHECK. REPOSITIONING PANEL PREVENTED FURTHER BINDING PROBLEMS.

AUS20040337

BOEING

GE  

 

TRANSDUCER

FAULTY

4/3/2004

74748E

CF680C2*

 

900040813

TE FLAPS

(AUS) LT IB TRAILING EDGE FLAP ROTARY VOLTAGE DIFFERENTIAL TRANSDUCER (RVDT) FAULTY.

AUS20040349

BOEING

PWA  

 

CABIN PRESSURE

MALFUNCTIONED

4/21/2004

767238

JT9D7R4E

 

 

 

(AUS) CABIN DIFFERENTIAL PRESSURE STUCK AT 8.6 PSI.

AUS20040341

BOEING

GE  

 

INDICATOR

FAULTY

4/7/2004

767338

CF680C2*

 

 

TE FLAP

(AUS) TRAILING EDGE FLAP DISAGREE INDICATION.

AUS20040342

BOEING

GE  

 

SELECTOR

FAULTY

4/18/2004

767338

CF680C2*

 

1305026

CABIN PRESSURE

(AUS) CABIN PRESSURE SELECTOR FAULTY.

AUS20040364

BOEING

GE  

 

BOLT

LOOSE

4/29/2004

767338

CF680C2*

 

 

FUEL/OIL COOLER

(AUS) LT TANK FUEL QUANTITY APPROXIMATELY 800 KILOGRAMS LOWER THAN RT TANK. INVESTIGATION FOUND THE FUEL/OIL COOLER FORWARD BASKET BOLTS LOOSE BUT ASCERTAINED THIS WAS NOT THE CAUSE OF THE APPARENT FUEL LOSS. INVESTIGATION CONTINUING.

AUS20040359

BOEING

GE  

 

SKIN

DELAMINATED

4/27/2004

767338

CF680C2*

 

 

RT SLAT

(AUS) RT LE SLAT T/E WEDGE DELAMINATED ON IB END UPPER FACE. AREA OF DELAMINATION APPROXIMATELY 70 SQ IN. FOUND DURING INSPECTION IAW AD/767/73.

AUS20040442

BOEING

GE  

 

PUMP

FAILED

3/15/2004

767338

CF680C2*

 

6506806

HYDRAULIC SYSTEM

(AUS) LT ENGINE DRIVEN HYDRAULIC PUMP FAILED DUE TO LOSS OF HYDRAULIC FLUID.

AUS20040391

BOEING

GE  

 

DOOR

MISSING

5/10/2004

767338

CF680C2*

 

311T106535

NACELLE

(AUS) NR 2 ENGINE NACELLE/STRUT OB ACCESS DOOR MISSING.

AUS20040382

BOEING

GE  

 

TIRE

DEFLATED

5/3/2004

767338

CF680C2*

 

165T0100530

LT MLG

(AUS) LT MAIN LANDING GEAR NR 5 TIRE DEFLATED. NO DAMAGE TO TIRE EVIDENT.

AUS20040352

BOEING

RROYCE

 

BATTERY  

FAULTY

4/27/2004

767338

RB211524*

 

BPS73

EMERGENCY LIGHT

(AUS) EMERGENCY LIGHTING SYSTEM POWER SUPPLY AND BATTERY M1395 FAULTY.

CA040603006

BOEING

PWA  

 

BRAKE

DISINTEGRATED

6/3/2004

7673Y0

PW4060

 

260881211

MLG 

(CAN) FAULT: NR 5 AFT BRAKE DIS-INTEGRATED ON T/O. ACTION: NR 5 BRAKE ASSY REPLACED IAW J/C 6-232A, NR 5 WHEEL ASSY REPLACED IAW J/C 6-232B.

CA040712005

BOLKMS

 

 

SERVO VALVE

CRACKED

6/25/2004

BK117A1

 

 

10546682

HYD ACTUATOR

(CAN) DURING A ROUTINE INSPECTION A MARK WAS DISCOVERED ON THE ATTACHMENT HEAD OF THE SLIDER OF THE SERVO VALVE. THE SLIDER INSPECTED WITH LIQUID PENETRANT WHICH INDICATED THAT THE SLIDER WAS CRACKED.

AUS20040343

BOLKMS

LYC  

 

FITTING

CRACKED

4/29/2004

BK117B1

LTS101750B1

 

1053040212

T/R GEARBOX

(AUS) TAIL ROTOR GEARBOX MOUNT CRACKED FROM BOLT HOLE.

CA040712003

BOLKMS

 

 

BEARING RACE

SPALLED

6/30/2004

BO105C

 

 

4638302024

TRANSMISSION

(CAN) TRANSMISSION SENT FOR OVERHAUL DUE TO METAL CONTAMINATION DETECTED WITH A CHIP LIGHT INDICATION. AFTER DISSASSEMBLY BEARING OUTER RACE FOUND TO HAVE SPALLING DAMAGE.

CA040420001

BOLKMS

ALLSN

 

STRUCTURE

DAMAGED

4/15/2004

BO105S

250C20B

 

10541227

ROTOR BRAKE BOX

(CAN) THE COLLECTIVE FRICTION ASSEMBLY WAS REPORTED FEELING LOOSE. LOOSENESS WAS TRACED TO THE BRAKE BOX, WHICH WAS MOUNTED WITH 6MM BOLTS IN 10MM HOLES.

CA040708010

BOMBDR

PWC  

 

PUMP

FAILED

7/6/2004

DHC8400

PW150A

 

6617302

NR 2 HYD SYSTEM

(CAN) DURING TEST FLIGHT, NR 2 HYD CAUTION LIGHT ILLUMINATED. CONFIRMED NO PRESSURE ON SYSTEM. QRH AND DIVERTED TO BASE. VERIFIED PUMP QUILL SHAFT SHEARED.

CA040526005

BOMBDR

PWC  

 

PROXIMITY SWITCH

MALFUNCTIONED

3/17/2004

DHC8400

PW150A

 

401020101

NLG 

(CAN) AFTER GEAR UP SELECTION, GEAR CAME UP AND LOCKED BUT NOSE GEAR DOOR LIGHT REMAINED ON. WHEN GEAR WAS SELECTED DOWN, THE NOSE GEAR DOOR CAUTION LIGHT REMAINED ON. (GEAR DOWN AND LOCKED). UNSCHEDULED LANDING COMPLETED. INVESTIGATION/ACTION, NOSE GEAR DOOR CLOSED PROXIMITY SENSOR REPLACED IAW AMM 32-61-00.

CA040526006

BOMBDR

PWC  

BFGOODRICH

WIRE

SHORTED

4/12/2004

DHC8400

PW150A

 

 

 

(CAN) AFTER DEPARTURE GEAR WOULD NOT RETRACT WHEN GEAR UP WAS SELECTED. GEAR WAS RECYCLED BUT WOULD STILL NOT COME UP. THE ONLY INDICATIONS WERE THREE GREEN AND THREE RED LIGHTS. NO CAUTION OR AURAL WARNINGS. THE FLIGHT WAS RETURNED TO BASE. INVESTIGATION/ACTION, NOSE WHEEL CENTERING SENSOR WIRING FOUND SHORTED. SENSOR REPLACED IAW AMM 32-61-00.

CA040415004

BRAERO

RROYCE

 

BELLCRANK

CRACKED

4/8/2004

HS7482A

DART5342

 

298G3096

ELEVATOR CONTROL

(CAN) ON PREFLIGHT INSPECTION, WHEN CHECKING ELEVATOR PLAY, EXCESSIVE MOVEMENT REVEALED THE ELEVATOR CONTROL BELLCRANK PRIMARY ATTACH LUG WAS CRACKED THROUGH AND ROD END WAS BEING RETAINED BY OVERSIZED SECONDARY LUG RESULTING IN A DECREASE OF TRAVEL ON STARBOARD ELEVATOR AND SUBSTANTIALLY INCREASED FREE PLAY. THE ELEVATOR ACTUATOR ROD WAS RETAINED BY THE RESTRICTING BRACKET, INTRODUCED BY MANDATORY MODIFICATION 2449/SB27-33. THERE IS NO REPORT OF THE AIRCRAFT RECENTLY EXPERIENCING ANY GUST LOADS TO THE ELEVATORS.

CA040520001

BRAERO

RROYCE

 

ENGINE

SEIZED

5/11/2004

HS7482A

DART5342

 

 

RIGHT

(CAN) THE AIRCRAFT WAS CLIMBING EN-ROUTE WHEN THE FLIGHT CREW OBSERVED THE RT ENGINE OIL PRESSURE RISING ABOVE LIMITS. THE ENGINE CEASED OPERATING AND THE PROPELLER FEATHERED BEFORE THE CREW COULD ACTION THE ENGINE SHUTDOWN CHECKLIST. SHUTDOWN AND CLEANUP CHECKLISTS WERE CARRIED OUT AND THE FLIGHT DIVERTED BACK TO MAIN BASE. THE FLIGHT CREW DECLARED AN EMERGENCY AND LANDED AT LAKE WITHOUT FURTHER INCIDENT. COMPANY MAINTENANCE FOUND THE ENGINE WAS SEIZED. THE ENGINE AND PROP WERE REPLACED AND THE AIRCRAFT RETURNED TO SERVICE. THE ENGINE WILL BE SHIPPED OUT TO A FACILITY FOR INSPECTION AS SOON AS PRACTICAL.

CA040624007

BRAERO

RROYCE

ROTOL

STRIP

SEPARATED

6/21/2004

HS7482A

DART5342

R212

 

PROP BLADE LE

(CAN) DEPARTING, AN UNUSUAL NOISE WAS DETECTED FROM THE NR 2 ENGINE. THE AIRCRAFT RETURNED TO POINT OF DEPARTURE. THE LEADING EDGE PROTECTION STRIP ON ONE BLADE WAS SEPARATED 6 INCHES AT THE OB END. MAINTENANCE REMOVED THE STRIPS FROM ALL 4 BLADES AND THE AIRCRAFT WAS RETURNED TO SERVICE AFTER GROUND RUN YIELDED NO VIBRATION OR UNUSUAL NOISE.

CA040520003

CESSNA

CONT

 

RETAINING RING

DISLODGED

5/20/2004

150M

O200A

 

640174

STARTER GEAR

(CAN) STARTER GEAR RETAINING RING (P/N 6401740) DISENGAGED FROM THE STARTER SHAFT AND LODGED IN THE STARTER GEAR NEEDLE BEARING (P/N 639788). THE NEEDLE BEARING FAILED WITH THE BEARING NEEDLES ENTERING THE ENGINE REAR CASE AND OIL SYSTEM. THE NEEDLES IN THE OIL SYSTEM DAMAGED THE FOLLOWING PARTS: OIL PUMP GEARS (2)P/N'S 3562 AND 21343 REAR CASE (1)P/N 640174STARTER DRIVE AND CLUTCH(1) P/N 641500.

AUS20040383

CESSNA

LYC  

 

SCREW

CRACKED

5/3/2004

152  

O235L2C

 

LW19339

ENGINE

(AUS) EXHAUST VALVE ROCKER ADJUSTMENT SCREW CRACKED ALLOWING LOCKNUT TO LOOSEN AND ADJUST VALVE CLEARANCE.

CA040415002

CESSNA

CONT

CONT

VALVE GUIDE

WORN

4/4/2004

172  

O300A

 

 

CYLINDER

(CAN) CYLINDER NR 3, NR 4 AND NR 5, EXCESSIVE OIL CONSUMPTION AND LOW COMPRESSION. ENGINE WAS RETURNED TO OVERHAUL FACILITY WHERE IT WAS DISCOVERED THAT 3 OF 6 CYLINDERS HAD EXCESSIVE PLAY IN THE EXHAUST VALVE GUIDES WHICH CAUSED THE VALVE TO BECOME COKED AND STICK IN THE GUIDE. CYLINDERS MFG. S/N: NR 3, 31109,NR 4, 31215, AND NR 5, 31213.

CA040415003

CESSNA

LYC  

 

CLEVIS BOLT

MISINSTALLED

3/25/2004

172M

O320E2D

 

AN2312

ELEVATOR

(CAN) INCORRECT INSTALLATION OF UPPER ELEVATOR CABLE TO ELEVATOR BELLCRANK. AFTER A RECENT PAINT JOB WHERE THE ELEVATOR HAD BEEN REMOVED, THE UPPER BOLT WAS INSTALLED INCORRECTLY. THE AIRCRAFT SERVICE MANUAL MAKES (SPECIAL NOTE) THAT THE UPPER CABLE MUST BE ATTACHED WITH BOLT HEAD ON RT, THIS SUPPLIES PROPER CLEARANCE BETWEEN BOTH HEAD AND ADJACENT STRUCTURE WITH THE BOLT INSTALLATION REVERSED. THE NUT (AN310-3) INTERFERED WITH ADJACENT BULKHEAD, THIS LIMITED UP ELEVATOR TRAVEL THE POSSIBILITY ALSO EXISTED THAT THE ELEVATORS COULD HAVE JAMMED IN THE FULL UP POSITION. THE AIRCRAFT HAD PREVIOUSLY FLOWN A TRAINING FLIGHT DOING INTENTIONAL STALLS AND SPINS.

CA040505003

CESSNA

LYC  

 

SKIN

CRACKED

4/27/2004

172M

O320E2D

 

 

LT TE FLAP

(CAN) SMALL CRACK WAS FOUND AT TRAILING EDGE OF THE LT FLAP.

CA040708009

CESSNA

LYC  

 

SKIN

CRACKED

6/11/2004

172M

O320E2D

 

 

RT FLAP

(CAN) SMALL CRACKS AT RIVETS, 4 PLACES, WERE FOUND ON THE RT FLAP.

CA040604006

CESSNA

LYC  

 

HINGE BRACKET

CRACKED

5/26/2004

172M

O320E2D

 

05310186

RUDDER

(CAN) DURING ROUTINE INSPECTION OF RUDDER THE BRACKET IN QUESTION WAS FOUND TO HAVE TWO CRACKS BESIDE THE THRUST SURFACE. DUE TO THE HIGH HOURS OF THIS ASSEMBLY THE THRUST SURFACE WAS FOUND TO HAVE WORN TO HALF OF ITS ORIGINAL THICKNESS. REPAIR TO THE RUDDER ASSEMBLY WAS ACCOMPLISHED BY REPLACEMENT OF ALL SIX HINGE BRACKETS. SUBSEQUENT INSPECTIION OF SIMILAR AIRCRAFT WITH SIMILAR TIME WERE FOUND TO HAVE SAME WEAR PATTERN BUT NO CRACKS PRESENT. FIVE MORE ASSEMBLIES HAD HINGE BRACKET REPLACEMENT DUE TO EXCESSIVE WEAR.

CA040713005

CESSNA

LYC  

 

PUSHROD

BENT

7/8/2004

172M

O320E2D

 

 

ENGINE CYLINDER

(CAN) PILOT WAS 10 MILES FROM AIRPORT. WHEN A POWER LOSS AND ENGINE VIBRATION WAS NOTED. PILOT INFORMED ATC OF SITUATION AND LANDED AT AIRPORT WITHOUT INCIDENT. UPON INVESTIGATION NOTICED NO COMPRESSION AND BENT PUSH ROD AND PUSHROD HOUSING ON NR 4 CYLINDER. NR 4 CYLINDER REPLACED WITH SERVICEABLE CYLINDER AND AIRCRAFT WAS RETURNED TO SERVICE.

CA040604008

CESSNA

LYC  

 

DOOR FRAME

CRACKED

5/25/2004

172M

O320E2D

 

 

FUSELAGE

(CAN) INSPECTION LOWER DOOR POST IAW SB 97-1 AND FOUND CRACK AT CORNER IAW SB. BOTH RT AND LT DOOR POSTS. REPAIRED WITH MFG REPAIR KIT.

CA040628004

CESSNA

LYC  

 

CONTROL CABLE

WORN

6/28/2004

172P

O320D2J

 

2520851

THROTTLE

(CAN) THIS IS THE SECOND OCCURRENCE OF SUCH A DEFECT NOTED BY THE SAME OPERATOR WITHIN THE PAST FEW WEEKS. THE SWAGED SWIVEL JOINT ON THE THROTTLE CONTROL WAS NOTED TO BE WORN TO THE POINT WHERE THE BALL END COULD BE REMOVED FROM ITS SWAGED SOCKET WITH EASE. DEFECT WAS DISCOVERED DURING ROUTINE INSPECTION.

AUS20040449

CESSNA

LYC  

LAMAR

DRIVE ASSY

SEIZED

5/24/2004

172R

IO360L2A

 

85104666

STARTER

(AUS) STARTER MOTOR BENDIX DRIVE SEIZED INTERNALLY.

AUS20040402

CESSNA

LYC  

 

RIB  

CRACKED

5/14/2004

172R

IO360L2A

 

053200199

HORIZONTAL STAB

(AUS) LH HORIZONTAL STABILIZER RIB AFT ATTACHMENT ANGLE CRACKED.

AUS20040358

CESSNA

LYC  

 

ANGLE

CRACKED

5/5/2004

172R

IO360L2A

 

053200199

HORIZONTAL STAB

(AUS) RT HORIZONTAL STABILIZER AFT RIB ATTACHMENT ANGLE CRACKED. A GAP BETWEEN THE AFT RIB ATTACHMENT ANGLE AND SPAR CAUSES CRACKING OF THE ANGLE WHEN THE ATTACHMENT BOLTS ARE TENSIONED. ON REMOVAL OF THE FORWARD STABILIZER ATTACHMENT BOLTS FRETTING WAS EVIDENT AND THE BOLTS WERE SHANK BOUND.

AUS20040412

CESSNA

LYC  

 

PIPE

CORRODED

4/27/2004

172RG

O360F1A6

 

248000131

HYD POWER PACK

(AUS) LANDING GEAR UP PIPE FROM GEAR SELECTOR HANDLE VALVE TO HYDRAULIC POWER PACK CORRODED WITH A SMALL PINHOLE LEAK. A FINE SPRAY OF HYDRAULIC FLUID CONTAMINATED THE REAR OF THE ADF RACK.

CA040607001

CESSNA

LYC  

 

WIRE

BROKEN

6/4/2004

177RG

IO360A1B6

 

20700291

NLG DOWNLOCK SW

(CAN) PILOT EXPERIENCED NO GEAR DOWN AND LOCK INDICATION LIGHT AFTER GEAR HAD COMPLETED CYCLE. AFTER AN UN-EVENTFUL LANDING AND INSPECTION, FOUND NOSE GEAR DOWNLOCK SWITCH WIRE WAS BROKEN AT BASE OF SWITCH.

CA040329003

CESSNA

CONT

 

GENERATOR

LOOSE

3/2/2004

180F

O470R

 

1101912R

ENGINE

(CAN) GENERATOR WAS FOUND TO BE LOOSE AND SLOPPY. UPON REMOVAL IT WAS DISCOVERED THAT FRONT LUG HOLE HAD BEEN PREVIOUSLY DRILLED AND BUSHED. BOTH GEN MOUNTING LUG HOLES WERE SEVERELY WORN AND ELONGATED, BOLTS WORN, AND BUSHING WORN WITHIN .1250 INCH OF SIDE OF LUG. GEN MOUNT BRACKET (P/N539579) HOLES ALSO ELONGATED. REPAIR REQUIRED NEW GENERATOR AND NEW MOUNT BRACKET. OWNER CLAIMS NO KNOWLEDGE OF PREVIOUSLY UNAPPROVED INSTALLATION OF BUSHING IN GENERATOR. UNAPPROVED REPAIR CAUSED DAMAGE TO MOUNT BRACKET. OWNERS SHOULD BE WARNED AGAINST INSTALLING BUSHINGS AT GEN ATTACH POINTS.

AUS20040392

CESSNA

CONT

 

BULKHEAD

CRACKED

1/13/2004

182B

O470*

 

0513006103

FUSELAGE

(AUS) FUSELAGE BULKHEAD CRACKED IN AREA DESCRIBED IN AD/CESSNA180/75AMDT2. CRACK LENGTH APPROXIMATELY 38.1MM (1.5IN). AD IS NOT APPLICABLE TO THIS MODEL AIRCRAFT.

CA040622003

CESSNA

CONT

 

CRANKCASE

CRACKED

9/25/2003

182F

IO470S

 

 

ENGINE

(CAN) CRANKCASE WAS DISCOVERED CRACKED NEAR OIL CAP LOCATION. CRANKCASE REPLACED.

AUS20040446

CESSNA

CONT

 

SPAR

CORRODED

5/26/2004

182F

O470R

 

122210523

RT WING

(AUS) RT WING MAIN SPAR ANGLE CONTAINED EXFOLIATION CORROSION IN AREA OF WING ATTACHMENT ANGLE.

CA040622004

CESSNA

CONT

 

CRANKCASE

CRACKED

5/6/2002

182J

IO520D

 

 

ENGINE

(CAN) WHILE CONDUCTING PRE-FLIGHT CHECK, OIL DRIPS WHERE NOTICED. AFTER VERIFICATION BY AN AMO, IT WAS DETERMINED THAT THERE WAS A SMALL CRACK IN THE CRANKCASE. ENGINE DISASSEMBLED AND CRANKCASE WAS REPLACED.

CA040322005

CESSNA

CONT

 

MAGNETO

FAILED

3/10/2004

182Q

O470U

 

103493504

ENGINE

(CAN) THE LT MAGNETO FAILED OPERATIONAL MAGNETO CHECK DURING PRE FLIGHT RUN-UP. AT TIMES THE RPM WAS NOTED TO HAVE DROPPED BY 200. DURING SUBSEQUENT TROUBLESHOOTING IT WAS NOTED THAT THE MAGNETO DROP WAS WELL WITHIN LIMITS AT 50 RPM BUT WOULD LATER DROP TO A TOTAL OF 200 RPM. EVERY 3 SECONDS THE RPM DROP WOULD CHANGE FROM 50/ 200 RPM. THE SAME CONDITION EXISTED AT HIGH POWER SETTINGS AS WELL. WITH BOTH MAGNETOS OPERATING AT HIGH POWER A SLIGHT RPM CYCLING COULD BE DETECTED. TWO LOWER SPARK PLUGS WERE REPLACED DUE TO CARBON FOULING. THE MAGNETO WAS REMOVED AND INSPECTED AND FOUND CONTAMINATED WITH ENGINE OIL DUE TO A FAILED SHAFT SEAL. UNIT WAS REPLACED AND THE AIRCRAFT GROUND CHECKED SERVICEABLE.

AUS20040434

CESSNA

LYC  

 

SUPPORT BRACKET

CRACKED

5/18/2004

182S

IO540AB1A5

 

07120591

FUSELAGE

(AUS) BATTERY SUPPORT BRACKETS CRACKED.

CA040413011

CESSNA

PWA  

 

PUMP

FAILED

4/9/2004

208B

PT6A114A

 

2C68 

FUEL BOOST

(CAN) DURING ROUTINE INSPECTION ALUMINUM PARTICLES WERE FOUND IN THE AIRFRAME FUEL FILTER DOWNSTREAM OF THE FUEL BOOST PUMP. RUNNING THE BOOST PUMP SHOWED THAT WHILE IT MAINTAINED OPERATING PRESSURE AN INTERMITTENT GRINDING NOISE COULD BE HEARD. DISSASEMBLY OF THE PUMP SECTION OF THE ASSEMBLY SHOWED THE TWO PIECE IMPELLER ASSEMBLY HAD BECOME DISBONDED.

CA040414001

CESSNA

PWA  

 

RETAINING RING

COLLAPSED

4/1/2004

208B

PT6A114A

 

3020159

COMPRESS SHROUD

(CAN) THE HOT SECTION WAS DISMANTLED FOR A SCHEDULED CT DISK REPLACEMENT. CT SHROUD SEGMENTS HAD SHIFTED AXIALLY. THE RETAINING RING HAD COME OUT OF THE GROOVE. THIS PROBLEM HAS BEEN DOCUMENTED ON OTHER ENGINES. MFG HAS ISSUED P/N 3110741-02 RETAINING RING ON SB 13121 (60A, 61, 62, 65 SERIES) AND SB 3248 (41/42, 45 SERIES) TO PREVENT THE COLLAPSE OF THE RETAINING RING. THE LATTER SB HAS NOT BEEN ISSUED ON SMALLER ENGINE MODELS SUCH AS THE 114A ENGINE MODEL TO ALLOW THE MORE ROBUST RETAINING RING TO BE USED.

AUS20040377

CESSNA

PWA  

 

SUPPORT

CRACKED

4/24/2004

208B

PT6A114A

 

26111441

FUSELAGE

(AUS) FLAP ACTUATOR SUPPORT ASSEMBLY CRACKED.

AUS20040361

CESSNA

CONT

 

HOSE

LOOSE

5/1/2004

210M

IO520L

 

S112940150

FUEL DISTRIBUTIO

(AUS) ENGINE FUEL HOSE LEAKING AT CONNECTION TO CHECK VALVE. FUEL LEAKING INTO ENGINE BAY. HOSE HAD NOT BEEN TIGHTENED DURING MAINTENANCE. PERSONNEL/MAINTENANCE ERROR.

AUS20040326

CESSNA

CONT

 

WEB  

CRACKED

4/5/2004

210R

IO520L

 

21320082

HORIZONTAL STAB

(AUS) TAILPLANE ATTACHMENT WEB CRACKED.

AUS20040360

CESSNA

CONT

 

OIL SYSTEM

CONTAMINATED

5/5/2004

310R

IO520M

 

IO520MB

ENGINE

(AUS) METAL CONTAMINATION OF RT ENGINE OIL SYSTEM. THREE PIECES OF 0.812 MM (0.032IN) LOCKWIRE FOUND IN OIL FILTER. TWO MORE PIECES OF LOCKWIRE FOUND IN OIL PRESSURE RELIEF VALVE. ENGINE HAD 6 HOURS OPERATION SINCE OVERHAUL. PERSONNEL/MAINTENANCE ERROR.

CA040604010

CESSNA

CONT

AIRBORNE

SHAFT

SHEARED

5/27/2004

402C

TSIO520VB

 

 

VACUUM PUMP

(CAN) VACUUM PUMP SHEAR SHAFT BROKE ON START.

CA040604011

CESSNA

CONT

AIRBORNE

SHAFT

BROKEN

5/27/2004

402C

TSIO520VB

 

 

VACUUM PUMP

(CAN) VACUUM PUMP SHEAR SHAFT, BROKE AFTER INSTALLED. REPLACED PUMP BY OTHER SOURCE.

CA040604005

CESSNA

CONT

 

BULKHEAD

DAMAGED

5/22/2003

414  

TSIO520NB

 

 

LT NACELLE

(CAN) DURING A SCHEDULED ENGINE CHANGE THE LT CANTED BULKHEAD ASSEMBLY ENGINE MOUNT STRUCTURE WAS FOUND TO HAVE BEEN DAMAGED BY EXHAUST GASES. THE INDIVIDUAL PARTS REQUIRING REPLACEMENT ARE AS FOLLOWS. 0851500-47 CAP0851500-39 CHANNEL 0851601-201 WEB FORWARD 0851601-27 WEB AFT. THE IPC DOES NOT GIVE A ASSEMBLY OR PN FOR THE CANTED BULKHEAD ITSELF.

AUS20040325

CESSNA

 

 

SPACER

WORN

4/21/2004

441  

 

 

57411541

MLG 

(AUS) MAIN LANDING GEAR UPLOCK HOOK ROLLER SPACER WORN.

AUS20040333

CESSNA

GARRTT

 

VALVE

LEAKING

4/21/2004

441  

TPE3318

 

69254313

FUEL CONTROL

(AUS) START FUEL VALVE LEAKING BETWEEN VALVE BODY AND SOLENOID.

AUS20040327

CESSNA

GARRTT

 

PUMP

CRACKED

4/24/2004

441  

TPE3318

 

31032174

ENGINE OIL

(AUS) ENGINE OIL PUMP HOUSING CRACKED.

AUS20040324

CESSNA

GARRTT

 

WIRE

WORN

4/27/2004

441  

TPE3318

 

99104207

FUEL INDICATING

(AUS) RT FUEL TANK QUANTITY WIRE CHAFED ON STRINGERS LOCATED AT STATION PWS 61.80.

AUS20040447

CESSNA

GARRTT

 

O-RING

DAMAGED

5/17/2004

441  

TPE3318

 

MS2877510

NLG ACTUATOR

(AUS) NOSE LANDING GEAR UPLOCK ACTUATOR O-RING DAMAGED. HYDRAULIC FLUID LEAKING FROM ACTUATOR BODY.

AUS20040448

CESSNA

GARRTT

 

SELECTOR VALVE

FAULTY

5/21/2004

441  

TPE3318

 

99102791

MLG 

(AUS) LANDING GEAR SELECTOR VALVE SOLENOID FAILED.

AUS20040368

CESSNA

GARRTT

 

BOOT

FAILED

4/29/2004

441  

TPE3318

 

27S70510904

DEICE SYS

(AUS) RT WING OUTER DE-ICE BOOT BURST AT THE UPPER SEAM AND SPLIT FOR THE ENTIRE LENGTH FROM THE OB RT NACELLE TO THE WINGTIP.

CA040326004

CESSNA

 

 

CONTROL VALVE

MALFUNCTIONED

3/22/2004

550  

 

 

 

MLG 

(CAN) AIRCRAFT DEPARTED, ON THE FIRST GEAR DOWN SELECTION THE LT MAIN GEAR DOWN LOCK INDICATION DID NOT ILLUMINATE. AN EMERGENCY EXTENSION PROCEDURE WAS PERFORMED WITH NO LT MAIN GEAR SAFE LIGHT VISIBLE. ON SHORT FINAL THE GEAR CIRCUIT BREAKERS WERE RESET TO DETERMINE GEAR SAFE CONDITION AND THREE GREEN WERE OBSERVED INITIALLY AND THEN THE LT GEAR SAFE LIGHT EXTINGUISHED. GEAR CIRCUIT BREAKERS WERE LEFT IN TO ENSURE POSITIVE HYDRAULIC SYSTEM DOWN PRESSURE TO THE GEAR. THE AIRCRAFT LANDED SAFELY AND RETURNED TO BASE. MAINTENANCE DETERMINED THAT THE MAIN LANDING GEAR CONTROL VALVE HAD MALFUNCTIONED AND REPLACED THE UNIT. THE GEAR RETRACTION SYSTEM WAS FUNCTION CHECKED AND THE AIRCRAFT RETURNED TO SERVICE.

CA040319005

CESSNA

PWA  

 

LINE

CHAFED

3/12/2004

550  

JT15D4

 

652635537

FUEL TANK

(CAN) DURING THE INSP PROCESS OF SB550-28-14, WING FUEL BOOST PUMP WIRING INSPECTION, IT WAS NOTED THAT BOOST PUMP WIRING WAS RUBBING ON MAIN EJECTOR TO CHECK VALVE ALUMINUM FUEL LINE P/N 6526355-37, CAUSING CHAFFING WEAR THROUGH FUEL LINE. THE WEAR WAS APPROX 75 PERCENT OF WALL THICKNESS ON LT FUEL TANK LINE AND 45 PERCENT ON RT FUEL TANK LINE. THERE WAS NO NOTICABLE WEAR THROUGH WIRING OUTTER INSULATION AROUND AREA IN CONTACT WITH LINE. BOTH LT AND RT FUEL LINES WERE REPLACED WITH NEW. SB KIT INCLUDES INSTALLATION OF NEW CLAMPS AND STAND OFFS TO HOLD THE BOOST PUMP WIRING AWAY FROM ALL STRUCTURE AND FUEL LINES AS WELL AS RE-ROUTE WIRE UNDER RATHER THAN OVER THE FUEL LINE NOTED.

CA040412010

CESSNA

PWA  

 

ANTENNA

BROKEN

3/20/2004

560XL

PW545A

 

14379

TENSIONER

(CAN) PILOTS REPORTED VIBRATION IN FLOORBOARDS 240 TO 260 KIAS AT ARRIVAL. DURING INSPECTION NOTICED THE HF ANTENNA BROKEN OFF AT THE TENSIONER UNIT ON FIN, THE COPPER WIRE BROKEN. THIS OCCURRED AT 2638.1 HRES AND 2308 CYCLES. THIS WIRE ANTENNA WAS REPLACED DEC 11/ 01 FOR EXACTILY THE SAME PROBLEM AT 1055.2 HRES AND 946 CYCLES. THIS CAUSED ONLY MINOR SCRATCHES ON THE TAILCONE. OUR MAIN CONCERN IS THE POSSIBILY OF THIS WIRE INTERFERING WITH THE FLIGHT CONTROLS. WE ARE EVALUATING THE NEED TO REPLACE THE WIRE ANTENNA ON A REGULAR BASIS (EVERY500 HOURS) TO PREVENT RE-OCCURRENCE.

CA040622006

CESSNA

LYC  

CESSNA

BRACKET

CRACKED

6/11/2004

A152

O235L2C

 

04320049

HORIZONTAL STAB

(CAN) THE BRACKET OF THE STABILIZER ASSEMBLY WAS FOUND CRACKED.

CA040709002

CESSNA

CONT

 

CYLINDER HEAD

CRACKED

6/23/2004

A185F

IO520D

 

649199P10A1

ENGINE

(CAN) CRACKED COMPLETELY THROUGH FROM ONE SPARK PLUG HOLE TO THE EXHAUST VALVE SEAT TOTHE OTHER SPARK PLUG HOLE. CYLINDER WAS REPAIRED 25.6 HOURS PREVIOUS. (DUE TO E XHAUST VALVE PROBLEMS) NOTE: LOGBOOK INCORRECTLY STATED CYLINDER WAS OVERHAULED. CYLINDER WAS ACTUALLY REPAIRED 25.6 HOURS PREVIOUS. CYLINDER FAILURE OF THIS TYPE IS NOT UNCOMMON ON LARGER 6 CYLINDER ENGINES.

CA040622005

CESSNA

CONT

 

BELT

FAILED

6/6/2004

T210L

TSIO520H

 

539547310

ALTERNATOR

(CAN) THE ALTERNATOR DRIVE BELT CAME OFF IN FLIGHT.

CA040709003

CESSNA

CONT

 

SCREW

WORN

7/1/2004

U206

IO550F

 

642335

OIL VALVE

(CAN) DURING ENGINE START, FIRST FLIGHT OF THE DAY, OIL PRESSURE WAS OBSERVED AS BEING TOO HIGH (75 PSI AT IDLE). SYSTEM BLOCKAGE WAS SUSPECTED, OIL FILTER INSPECTED (CLEAR), OIL DRAINED AND INSPECTED (CLEAR), PRESSURE CHECKED AT OTHER PRESSURE POINTS IAW MFG SERVICE REP. INSTRUCTIONS. (AIRFRAME INDICATOR ACCURACY CONFIRMED.) NIL DEFECT FOUND. OIL PRESSURE RELIEF VALVE REMOVED, VISUALLY INSPECTED (NIL DEFECTS OBSERVED, REINSTALLED. ENGINE GROUND RUN, NIL CHANGE IN OIL PRESSURE. RELIEF VALVE ADJUSTING SCREW TURNED OUTWARD TO STOP. OIL PRESSURE OBSERVED (JUST IN RANGE). VALVE ASSEMBLY REPLACED WITH SERVICEABLE UNIT, OPERATION NORMAL.

AUS20040455

CESSNA

CONT

 

BOLT

CRACKED

5/24/2004

U206G

IO520*

 

NAS14740

MLG 

(AUS) UNDERCARRIAGE SADDLE BOLT CRACKED.

AUS20040445

CIRRUS

CONT

 

SEAT BELT

FAULTY

1/30/2004

SR20

IO360E

 

 

COCKPIT

(AUS) PILOTS SEAT BELT SHOULDER HARNESS DOES NOT FULLY RETRACT INTO INERTIA REEL. INVESTIGATION FOUND A STOP INSTALLED IN THE WEBBING IN AN AREA JUST BELOW JUNCTION.

CA040623005

CNDAIR

PWA  

BFGOODRICH

HOUSING

CRACKED

6/23/2004

CL2151A10

CA18

 

260414126629

PISTON

(CAN) HOUSING CRACKS FOUND AT OVERHAUL DURING LPI NDT OF BRAKE UNIT. THERE HAS BEEN PREVIOUS FINDINGS OF CRACKS IN SERVICE AND AT OVERHAULS OF OTHER BRAKE UNITS. (SEE SDR 20030619008) LEAKING BRAKE COULD BE INDICATION OF CRACKED BRAKE HOUSING. EXCESSIVELY WORN BRAKE COULD PROMOTE DISTORTION OF HOUSING, CREATING CRACKING.

CA040430006

CNDAIR

PWA  

WOODWARD

SOLENOID

FAILED

4/27/2004

CL2151A10

CA3  

 

321475

PROP GOVERNOR

(CAN) DURING A TEST FLIGHT THE RT ENGINE WAS SHUT DOWN AND THE PROP FEATHERED AS PART OF THE TEST FLIGHT PROCEDURE. THE FLIGHT CREW WAS UNABLE TO UNFEATHER THE PROPELLER. THE AIRCRAFT RETURNED TO THE AIRPORT AND LANDED SAFELY. UPON INVESTIGATION BY MAINTENANCE THE FEATHERING SOLENOID ON THE PROP GOVERNOR WAS FOUND TOBE AT FAULT. THE SOLENOID WAS REPLACED AND THE SYSTEM FUNCTION CHECKED SERVICEABLE.

CA040602008

CNDAIR

LYC  

 

FITTING

CORRODED

6/2/2004

CL600*

ALF502*

 

200811218

NLG AXLE

(CAN) 5 YEAR DETAILED INSPECTION REVEALED CORROSION PITTING BEYOND MANUFACTURER'S LIMITS, INTERNAL, BETWEEN NLG SLIDING TUBE (P/N 200811707)AND AXLE FITTING. NEW PART INSTALLED. THE AXLE FITTING WAS PREVIOUSLY REPLACED IN JUNE 1999 DURING THE 10 YEAR RESTORATION OF THE GEAR AT 2503 CSN.

CA040413002

CNDAIR

LYC  

SUNDSTRANDAI

VOLT REGULATOR

FAILED

4/7/2004

CL600*

ALF502R

 

720846B

GCU 

(CAN) IN FLIGHT LOSS OF NR 2 AC BUSS SERVICES CAUSED BY NR 2 GENERATOR DROPPING OFF LINE. RESET ATTEMPTS FAILED. DUE TO AN AD IN EFFECT ON THE REMAINING GENERATOR, A LANDING AT THE NEAREST AIRPORT WAS CARRIED OUT. DURING FAULT ISOLATION IT WAS FOUND THAT THE GENERATOR WAS DISPLAYING AN OVER VOLTAGE CONDITION ON THE VOLTAGE CHECK. THE NR 2 GCU WAS SWAPPED WITH NR 1 AND THE OVER VOLTAGE CONDITION TRANSFERRED TO THE NR 1 SYSTEM. AS THE VOLTAGE REGULATOR SECTION OF THE GCU IS BELIEVED TO BE AT FAULT, SERVICEABLE GCU WAS INSTALLED AND NORMAL SYSTEM OPERATION WAS RESTORED.

CA040322004

CNDAIR

GE  

 

PUMP

CONTAMINATED

3/22/2004

CL6002B19

CF343A1

 

848847

HYD SYS

(CAN) FAULT:AFTER TAKE-OFF MASTER WARNING AND GEAR DISAGREE MSG ON EICAS. ACTION: FOUND METAL CONTAMINATION IN HYD. SYST. NR 3, IN RETURN PRESS, CASE DRAIN FILTERS. ALL FILTERS REPLACED AND SYSTEMS FLUSHED IAW AMM 29-10-00-617-803. HYD PUMPS 3A, B REPL'D. NOSE GEAR STRUT SERVICED AND G/SWING C/OUT IAW AMM 32-20-00. ACFTSERV.

CA040318007

CNDAIR

GE  

 

THRUST REVERSER

MALFUNCTIONED

3/18/2004

CL6002B19

CF343A1

 

 

RIGHT

(CAN) EICAS MSG R REV. UNLOCKED DISPLAYED DURING FINAL APPROACH. ENG POWER WAS AT IDLE. NOTICED AC ROLL AND YAW. EMERGENCY STOW SELECTED AND A/P DISCONNECTED. RT REVERSER NOT SELECTED ON LANDING ROLL. REVERSER DEACTIVATED AND AC DXD UNDER MEL. VERBAL COMMENT FROM THE CREW WAS THAT THEY FELT THE REVERSER HAD UNLOCKED/PARTIALLY DEPLOYED FLT RECORDER PULLED FOR FURTHER EVALUATION.

CA040604016

CNDAIR

GE  

 

TIRE

SEPARATED

5/11/2004

CL6002B19

CF343B1

 

H29X901516

MLG 

(CAN) THE NR 2 MLG TIRE HAD SEPARATED THAT INCURRED DAMAGE TO THE IB FLAP SURFACE, FLAPSTUB FAIRING AND 3 FAN BLADES..

CA040623006

CNDAIR

GE  

 

BOLT

SEIZED

6/4/2004

CL6002B19

CF343B1

 

NAS620760D

PAX DOOR

(CAN) PILOT REPORTED MAIN PASSENGER DOOR DIFFICULT TO OPEN FROM OUTSIDE, HAD TO ENTER FROM SERVICE DOOR TO ACCESS AIRCRAFT. TRIED TO OPEN DOOR AND HANDLE WAS DIFFICULT TO TURN. MAINTENANCE FOUND AIRSTAIR PIVOT FITTING ASSEMBLY WAS SEIZED. UPON DISMANTLING THE ASSEMBLY, IT WAS NOTED THAT THE BOLT P/N NAS6207-60D WAS CORRODED AND SEIZED PREVENTING FREE OPERATION WITHIN THE PHENLOIC BUSHING. ASSEMBLY WAS REPLACED.

CA040326003

CNDAIR

GE  

AERO

GEARBOX

BINDING

3/22/2004

CL6002B19

CF343B1

 

 

THROTTLE CONTROL

(CAN) PILOT REPORTED THROTTLE ACTION STIFF. MAINTENANCE TROUBLESHOT PROBLEM TO NR 1 ENGINE THROTTLE CONTROL GEARBOX BINDING. NR 1 THROTTLE CONTROL GEARBOX REPLACED. IT IS NOTED THAT AD CF-2004-01, HAS BEEN ISSUED AGAINST GEARBOX P/N 2100140-007, ALTHOUGH IN THIS CASE IT WAS A PILOT REPORTED DEFECT AND NOT AS A RESULT OF AN INSPECTION IAW THE AD.

CA040417001

CNDAIR

GE  

 

FAIRING

LIGHTNING STRIKE

4/13/2004

CL6002B19

CF343B1

 

600220591008

HORIZONTAL STAB

(CAN) FLYING THRU SHOWERS AT 10000 FEET , ON ARRIVAL, LARGE FLASH WAS OBSERVED. NO AIRCRAFT SYSTEM AFFECTED. AFTER LANDING, 2 BLACK MARKS WERE FOUND ON THE LOWER RT HORIZONTAL STABILIZER. REPAIR EO 670-55-12-153 ALONG WITH NON DESTRUCTIVE TEST (NDT) CARRIED OUT AND AIRCRAFT RETURNED TO SERVICE.

CA040428002

CNDAIR

GE  

 

FAIRING

LIGHTNING STRIKE

4/27/2004

CL6002D24

CF343B1

 

6001038841

WX RADAR

(CAN) LIGHTNING STIKE ON APPROACH INTO AIRPORT. LIGHTNING ENTERED LT SIDE OF WEATHER RADAR. NO OBVIOUS EFFECT TO AIRCRAFT SYSTEM

CA040318009

CNDAIR

GE  

 

ENGINE

FAILED

3/17/2004

CL6002D24

CF343B1

 

 

RIGHT

(CAN) WHILE CARRYING OUT RELIGHT TESTS, RT ENGINE DID NOT RELIGHT VIA WINDMILL OR ATS.EMERGENCY WAS DECLARED AND SUCCESSFULL SINGLE ENGINE APPROACH WAS COMPLETED WITHOUT FURTHER INCIDENT. RT ENGINE WAS REPLACED AND AC FLOWN SINCE WITHOUT FURTHER INCIDENTS.

CA040603004

CNDAIR

GE  

 

AILERON

MISMANUFACTURED

6/3/2004

CL6012A12

CF341A

 

40E228410693

AUTO PILOT

(CAN) WHILE INVESTIGATING A SNAG, DISCOVERED AN AILERON A/P QUADRANT ASSEMBLY P/N 40E22-84-1069-1 WHICH DID NOT MEET THE MANUFACTURER'S DRAWING IN THE INSTALLATION OF THE NR 1 COLLINS A/P SERVO, LOCATED IN THE LT MLG WHEEL WELL. FOR THE DISABLING OF THE NR1 A/P SYSTEM, PENDING THE MANUFACTURING OF A NEW QUADRANT BY A PRECISION MACHINE SHOP.

CA040413001

CNDAIR

GE  

 

SPRING

MISSING

4/4/2004

CL604

CF34*

 

 

SEAT BELTBUCKLE

(CAN) PASSENGER SEATBELT BUCKLE WAS FOUND TO HAVE NO SPRING TENSION IN THE LOCK POSITION. THE DRIVE SCREW PIN HAD BACKED OFF .0312 WHICH ALLOWED TENSION TO RELEASE. BELT ASSEMBLY IS SAFTEY PRODUCTS. THE BUCKLE IS STAMPED. THIS IS A MID COAST STC INTERIOR INSTALLATION. ITEM P/N BL/6-3800BOB54TSA REV. A

CA040602004

CNDAIR

GE  

 

VALVE

GOUGED

6/2/2004

CL604

CF343B1

 

9795804

CABIN AIR

(CAN) THE LOW LIMIT VALVE WAS OBSERVED TO STICK IN AN OPEN POSITION AND WOULD NOT MODULATE. AFTER REMOVAL OF THE VALVE THE BUTTERFLY WAS FOUND TO BE SCRAPING AGAINST THE BODY OF THE VALVE.ANOTHER VALVE WITHTHIS CONDITION HAD PREVIOUSLY BEEN FOUND TO SHEAR THE BUTTERFLY SHAFT COMPLETLY. REF. SDR 2004051401.

CA040602005

CNDAIR

GE  

 

TURBINE

SEIZED

6/2/2004

CL604

CF343B1

 

 

APU 

(CAN) DURING INITIAL START AN UNUSUAL NOISE WAS HEARD FROM THE APU. THE UNIT WAS RUN FOR APPROXIMATELY ONE HOUR WITH NO ABNORMAL INDICATIONS. UPON FURTHER INVESTIGATION OF THE NOISE IT WAS DISCOVERED THAT IT WAS NOT POSSIBLE TO ROTATE THE TURBINE WHEEL BY HAND. A PARTIAL TURBINE SEIZURE WAS IDENTIFIED. THE APU WAS REMOVED AND SENT FOR REPAIR.

CA040325005

CVAC

ALLSN

 

DOOR

LEAKING

3/25/2004

340CVAC

501D13D

 

 

CARGO

(CAN) ON CLIMB OUT, CREW EXPERIENCED A LOSS OF CABIN PRESSURE AND A CORRESPONDING DOOR WARNING LIGHT. THE CREW RETURNED TO DEPARTURE, CYCLED THE C1 DOOR, AND RE-DEPARTED WITHOUT FURTHER INCIDENT.

CA040628005

CVAC

ALLSN

 

DOOR

FAILED

6/25/2004

440  

501D13D

 

315341

OIL COOLER

(CAN) DURING CLIMB OUT THE FLIGHT CREW NOTICED THE OIL TEMPERATURE RISING TO THE RED LINE. THE OIL COOLER SWITCH WAS SELECTED FROM (AUTO) TO (MANUAL) OPEN WITH NO RESOMNSE. THE OIL TEMPERATURE CONTINUED TO CLIMB. THE ENGINE WAS SHUT DOWN ANDTHE PROP WAS FEATHERED. THE AIRCRAFT RETURNED TO BASE. DURING TROUBLESHOOTING, MAINTENANCE STAFF FOUND THE OIL COOLER DOOR ACTUATOR WAS INOPERATIVE. THE OIL COOLER DOOR ACTUATOR WAS REPLACED AND THE AIRCRAFT WAS RETURNED TO SERVICE.

AUS20040398

DHAV

DHAVXX

 

SCAVENGE PUMP

CRACKED

5/6/2004

DCH1CHIPMUNK

GIPSYMAJOR1

 

H40671B2

ENGINE

(AUS) ENGINE OIL SCAVENGE PUMP CRACKED.

CA040622002

DHAV

PWA  

 

BRACKET

CRACKED

6/8/2004

DHC2MK1

R985AN14B

 

 

LT FLOAT

(CAN) LT FLOAT REAR DOCK FITTING SADDLE BRACKETS CRACKED AT BOLT HOLES.

CA040713004

DHAV

PWA  

 

BOLT

WORN

6/30/2004

DHC2MK1

R985AN14B

 

AW46 

RT ELEVATOR

(CAN) DURING SCHEDULED INSPECTION RT ELEVATOR FOUND SLIGHTLY LOOSE AT TORQUE TUBE. NUT COULD NOT BE TIGHTENED DUE TO EXCESSIVELY WORN BOLT AW4-6. BOLT REPLACED AND NUT AN320-4. ELEVATORS MUST BE REMOVED EVERY 400 HOURS TO ACCOMPLISH AD 80-25. REPEATED REMOVAL AND INSTALLATION OF ELEVATOR CAUSING PREMATURE WARE OF THESE BOLTS AND POSSIBLE SUBSEQUENT ELONGATION OF HOLES TORQUE TUBE. SUGGEST REVIEW OF AD 80-25 IS IT NECESSARY SO OFTEN.

CA040628001

DHAV

PWA  

 

ENGINE

FAILED

6/16/2004

DHC3

R1340AN1

 

R1340S3H1G

 

(CAN) ENGINE SEIZED IN CRUISE FLIGHT. CASE BROKEN.

CA040713007

DHAV

PWA  

 

CYLINDER HEAD

CRACKED

7/5/2004

DHC3

S3H1G

 

AE92181ER

ENGINE

(CAN) CRACK IN HEAD WALL BETWEEN FINS 11 AND 12 COUNTING FROM BARREL, ON EXHAUST SIDE OF CYLINDER.

CA040712001

DHAV

PWA  

 

CAP  

LEAKING

6/18/2004

DHC6300

PT6A27

 

 

AFT TANK FUEL

(CAN) LANDED BACK TO THE BASE, DUE TO FUEL LEAKAGE FROM FUEL CAP INTO THE CABIN. ON ARRIVAL FOUND SIGN OF FUEL LEAKAGE AT AFT TANK CAP TO THE ADJACENT PAX DOOR INTO THE CABIN. AFT TANK WAS FULL ON DEPARTURE, SUSPECT FUEL SEEPAGE FROM THE TANK CAP DUE TO SEAL WAS NOT IN GOOD CONDITION. TANK CAP REPLACED.

CA040413013

DHAV

PWA  

LUCAS

FAN  

BROKEN

4/8/2004

DHC6300

PT6A27

 

230481490

STARTER GEN

(CAN) DURING INSTALLATION OF FAN PN 230481490 AT OVERHAUL, THE CENTER PART OF THE FAN BROKE AWAY FROM THE FAN BODY AND BLADES. THE CAST ALUMINUM FAN WAS BEING ATTACHED TO THE SHAFT, ARMATURE AND BEARING ASSY WHEN IT BROKE CIRCUMFERENTIALLY BEFORE REACHING TARGET TORQUE ON THE SHAFT NUT OF 110 INCH-LBS. THE BREAK APPEARS TO BE A CLEAN BREAK, IE THERE IS NO SIGN OF A PRE-EXISTING CRACK. PART WAS REPLACED BY AN ALTERNATE P/N 23048-1240. BROKEN FAN HAS BEEN QUARANTINED.

CA040414003

DHAV

 

 

SOLENOID

MALFUNCTIONED

3/9/2004

DHC7*

 

 

664901

FLAP DUMP

(CAN) SCREWS ON THE SECOND STAGE FLAP DUMP SOLENOID VALVE BROKE AND CAUSED THE TRAILING FLAPS TO MALFUNCTION. NO FLUID WAS LOST. PART WAS REPLACED AND AIRCRAFT RETURNED TO SERVICE. PART SENT TO MFG FOR INVESTIGATION.

CA040413007

DHAV

 

 

ACTUATOR

DISLODGED

3/1/2004

DHC7*

 

 

2651001011

SPOILERS

(CAN) DURING CRUISE FLIGHT LT ROLL SPOILER ACTUATOR BROKE OFF ITS MOUNTS. NR 2 HYDRAULIC SYSTEM WAS LOST DUE TO A HYDRAULIC LEAK FROM THE ACTUATOR. AIRCRAFT LANDED SAFELY. PROBLEM WAS FOUND TO BE A PRE MOD ROLL SPOILER ACTUATOR WHICH THE OPERATOR HAD NOT UPDATED TO THE IMPROVED.

CA040713006

DHAV

PWA  

 

FCU  

FAILED

6/20/2004

DHC7102

PT6A50

 

32447531917

ENGINE

(CAN) AT CRUISE ALTITUDE AT FL110 ON A MEDEVAC FLIGHT DESCENT CHECKS WERE CARRIED OUT. AS TURBULENCE WAS EXPECTED A RATE OF 500 RPM AND SPEED OF 170 KIAS WAS BRIEFED AFTER DESCENT. CLEARANCE RECEIVED POWER LEVERS WERE PULLED BACK TO APPROX 3000 TORQUE. NR 3 ENG TORQUE, RPM, T5 AND NG REMAINED AT CRUISE POWER. SEVERAL POWER LEVER EXCURSIONS WERE CARRIED OUT BUT THERE WAS NO CHANGE. CAPT CALLED FOR QRH ACTION. ENGINE NR 3 SHUT DOWN IAW QRH. ATC NOTIFIED. ERV REQUESTED. A 3 ENG LANDING CARRIED OUT. AFTER AC SHUT DOWN ON RAMP, MAINTENANCE STAFF REMOVED NR 3 COWLING TO DETERMINE IF LINKAGE HAD FAILED. INITIAL ASSESSMENT WAS FAILURE OF FUEL CONTROL UNIT. SUBSEQUENT APPROVAL RECEIVED TO CONDUCT 3 ENGINE FERRY FLIGHT.

CA040623004

DHAV

PWA  

 

LINK

CRACKED

5/25/2004

DHC8102

PW120A

 

89925

NLG STEERING

(CAN) DURING A ROUTINE LAYOVER CHECK THE STEERING LINK ON THE NOSE STEERING ACTUATOR WAS DISCOVERED TO HAVE A CRACKED END FITTING WHERE THE CENTER PIVOT PIN PASSES THROUGH AND MATES WITH THE ADJOINING LINK. THE END FITTING WAS STRETCHED OPEN AND THE THIN RING END BROKEN AWAY. ALL LINKS AND PINS WERE REMOVED AND INSPECTED WITH NO ADDITIONAL DAMAGE DETECTED. THE DEFECTIVE LINK WAS REPLACED. THERE WAS NO INDICATION OF A STEERING PROBLEM REPORTED BY THE FLIGHT CREW.

CA040712002

DHAV

PWA  

 

CONNECTOR

FAILED

7/7/2004

DHC8102

PW120A

 

MS347L2255PN

LT WING ROOT

(CAN) ON TAKE OFF ROLL 40-50 KNOTS THE NR 1 PROPELLER GAUGE WENT TO ZERO ON BOTH DIGITAL AND ANALOG DISPLAYS. ALL OTHER ENGINE GAUGES NORMAL. MAINTENANCE CARRIED OUT AN INSPECTION AN FOUND TWO PINS (Z AND FF) IN CONNECTOR 9811-P13 (P/N MS3476L22-55PN) TO BE CORRODED AND TO BE AT FAULT WHEN MEGGARED. CONNECTOR REPLACED.

CA040622001

DHAV

PWA  

 

HOSE

LEAKING

6/21/2004

DHC8102

PW120A

 

DSC252B40124

NR 2 HYD SYSTEM

(CAN) ENROUTE, THE CREW NOTICED SLOW BUT STEADY DEPLETION OF HYDRAULIC SYSTEM 2 . THE QUANTITY DOWN TO 2 QUARTS. CREW RETURNED AIRCRAFT BACK WHERE MAINTENANCE PERSONAL UPON INVESTIGATION FOUND THE HOSE TO THE DRAG STRUT ACTUATOR IN THE NOSE GEAR BAY LEAKING. THE HOSE WAS REPLACED WITH A NEW UNIT AND TESTS PERFORMED IAW ATA 32-30-31 AND A/C WAS RETURNED TO SERVICE.

CA040415008

DHAV

PWA  

 

VALVE

SLOW

3/28/2004

DHC8102

PW120A

 

58570

PARK BRAKE

(CAN) ON TAXI TO HANGER, BRAKES OVERHEATED CAUSING FIRE ON NR 3 AND NR 4 MAIN WHEEL ASSEMBLIES AND NR 1 AND NR 2 BRAKE ASSEMBLIES TO GLOW RED HOT. ALL FOUR MAIN WHEEL AND BRAKE ASSEMBLIES REPLACED. RT MAIN LANDING GEAR SHOCK STRUT REPLACED. OTHER ITEMS, BRAKE LINES, FIRE EXTINGUISHERS, ETC REPLACED AS REQUIRED. EXTENSIVE TROUBLESHOOTING COMPLETED AND FAULT TRACED TO PARKING BRAKE VALVE SLOW TO RELEASE. TEAR DOWN REPORT STATES.

AUS20040419

DHAV

PWA  

 

SEAL

FAILED

4/4/2004

DHC8202

PW123D

 

571488

HYD SYSTEM

(AUS) NR 2 HYDRAULIC STANDBY POWER UNIT DRIVESHAFT SEAL FAILED. LOSS OF HYDRAULIC FLUID.

CA040622007

DHAV

PWA  

 

VENTURI

FAILED

6/22/2004

DHC8301

PW123

 

311269001

ADAPTER

(CAN) AFTER SHUTDOWN DUE TO UNSUCCESSFUL TRIM RUNS, IT WAS DISCOVERED THAT THE ADAPTER VENTURI P3 BLEED AIR PIPE LOCATED ON THE NR 1 ENGINE (S/N TM123038 ) THERE WAS 1 INCH X 1 INCH HOLE IN THE PIPE. THERE IS A CRACK THAT HAS PROPOGATED AND CAUSED THE PIPE TO FAIL.

CA040625001

DHAV

PWA  

 

CHECK VALVE

LEAKING

4/23/2004

DHC8301

PW123

 

3158223

HYD SYSTEM

(CAN) ON APPROACH AND AFTER LANDING GEAR DOWN SELECTION COMPLETED, NR 2 HYDRAULIC SYSTEM INDICATED LOSS OF ALL FLUID. APPROACH TO LANDING WAS CONTINUED, FOLLOWING A NORMAL LANDING, CREW INSPECTED AC AND CONFIRMED A SIGNIFICANT HYDRAULIC LEAK FROM AIRCRAFT'S EMPENNAGE AREA. FLIGHT WAS TERMINATED AND ENGINEERING ASSISTANCE REQUESTED. ENGINEERING INVESTIGATION CONFIRMED METAL FATIGUE FAILURE OF A CHECK VALVE BODY, WHICH ALLOWED LIBERATION OF ALL OF NR 2 HYDRAULIC SYSTEM FLUID TO ATMOSPHERE. FAILED CHECK VALVE WAS REPLACED AND FOLLOWING SERVICING OF THE NR 2 HYDRAULIC SYSTEM AIRCRAFT WAS RETURNED TO SERVICE. IT WAS NOTED THAT INSIDE OF THE VALVE SHOWED SIGNS OF CORROSION.

CA040625009

DHAV

PWA  

 

HOSE

LEAKING

6/23/2004

DHC8301

PW123

 

AE2463510E0124

HYD SYSTEM

(CAN) ON SELECTING GEAR RETRACTION AFTER TAKE-OFF , LOSS OF 32 SYSTEM HYDRAULIC FLUID. CAUTION LIGHTS FOR NR 2 HYD ISOLATION SYSTEM AND NR 2 HYD PUMP. AIRCRAFT RETURNED TO DEPARTURE AIRPORT AND USED ALTERNATE GEAR EXTENSION SYSTEM. NORMAL LANDING. MAINTENANCE INSPECTION FOUND NLG UP LOCK HYDRAULIC LINE FAILED. LINE REPLACED, HYDRAULIC SYSTEM SERVICED AND AIRCRAFT RETURNED TO SERVICE. THIS PART IS TRACKED AS AN EXPENDABLE AND ACCURATE PART. COMPANY HAS INHOUSE TASK TO REPLACE THIS LINE AT A C1 CHECK IF MANUFACTURE DATE CODE IS IN EXCESS OF 8 YEARS. LAST C1 CHECK ON THIS AIRCRAFT NOV/2003. HOSE DATE CODE 1/97

CA040628002

DHAV

PWA  

 

CONTACTOR

FAILED

6/26/2004

DHC8311

PW123

 

AA4N 

ENGINE NACELLE

(CAN) AFTER ENGINE START AND GPU REMOVAL THE PASS DOOR, BAG DOOR, FWD DOOR, AND SERVICE DOOR LIGHTS WERE FLASHING, WE RECONNECTED THE GPU, AND SHUTDOWN THE BOTH ENGINES. LIGHT SMOKE WAS OBSERVED FROM THE LT NACELLE AIRCRAFT WAS DEPLANED. THE AMOUNT OF SMOKE INCREASED AND FIRE BOTTLES WERE DICHARGED AND ALL POWER SHUT OFF. FOUND THE 2431K1 RELAY SHORTED, RELAY AND STARTER REPLACED.

CA040417002

DHAV

PWA  

 

SEQUENCE VALVE

INOPERATIVE

4/14/2004

DHC8311

PW123

 

69210

MLG 

(CAN) ON APPROACH , THE CREW SELECTED GEAR DOWN, NOSE GEAR WOULD NOT COME DOWN, AMBER AND RED CATION AND WARNING LIGHTS ON AND LOUD GRINDING NOISE IN NOSE WHEEL AREA WAS HEARD, THE CREW CARRIED OUT AN ALTERNATE GEAR SELECTION (THE ABOVE IS EXTRACTS FROM PILOT'S REPORT ) SEVERAL GEAR SWINGS COMPLETED AND WAS UNABLE TO DUPLICATE THE SNAG. SEQUENCE VALVE REPLACED FOR TROUBLE SHOOTING. SEVERAL MORE GEAR SWINGS COMPLETED WITH NO FAULT FOUND. SEQUENCE VALVE WAS SENT FOR TEAR DOWN REPORT, WILL UPDATE AS REPORT BECOME AVIALABLE.

CA040326002

DHAV

PWA  

 

BLADE

BENT

3/19/2004

DHC8311

PW123

 

 

IMPELLER

(CAN) ON TAKE OFF, CREW HEARD A STRANGE WHINING SOUND. SOUND IDENTIFIED AS FROM NR 1 ENGINE. TAKE OFF REJECTED AT 30 KTS. MAINTENANCE FOUND BENT BLADE ON LOW PRESSURE COMPRESSOR IMPELLER. ENGINE REPLACED. CREW ON PREVIOUS FLIGHT HAD REPORTED A BIRD STRIKE. AIRCRAFT HAD BEEN INSPECTED BY MAINTENANCE WITH NO APPARENT DAMAGE FOUND. ENGINE S/N TSN:23746 HRS, TSO:10578 HRS,CYCLES:34323. HOURS AND CYCLES ON IMPELLER BLADE TO BE DETERMINED.

CA040526001

DHAV

PWA  

 

PSEU

FAILED

5/24/2004

DHC8311

PW123

 

858601

MLG 

(CAN) FLIGHT CREW REPORTED UPON SELECTION OF GEAR DOWN, INITIALLY THREE GREEN INDICATED, SHORTLY AFTER, A FLICKERING OF THE NOSE GEAR DOOR (AMBER) AND UNSAFE (RED) AND HORN SOUNDED, THEN CLEARED. ON TAXI IN SNAG RE-OCCURRED AND GREEN GEAR SAFE LIGHT NOW U/S. ALTERNATE VERIFICATION LIGHTS INDICATED GEAR SAFE. MAINTENANCE FOUND CARD FAULT ON PSEU. REPLACED AND TESTED UNIT AND COMPLETED GEAR SWINGS WITH NO FAULTS FOUND. AIRCRAFT WAS RETURNED TO SERVICE. SNAG RE-OCCURRED FOUR FLIGHTLEGS LATER WITH INDICATION OF GEAR UNSAFE ON TAXI. AIRCRAFT IS CURRENTLY IN HANGAR BEING INVESTIGATED.

AUS20040420

DHAV

PWA  

 

CONNECTOR

BURNED

4/21/2004

DHC8315

PW123

 

2067051

LIGHTS

(AUS) RH OVERHEAD LIGHTING TERMINAL 7 CONNECTOR BURNED AND DAMAGED.ADJACENT TERMINAL 6 ALSO HEAT DAMAGED.

AUS20040407

DHAV

PWA  

HAMSTD

SEAL

INCORRECT

5/12/2004

DHC8315

PW123

 

8173881

PROPELLER BLADE

(AUS) LT PROPELLER NR 4 BLADE SEAL FAILED. INSPECTION OF THE REMOVED SEAL REVEALED THE SEAL TO BE A SEAL FOR A 14SF TYPE PROPELLER WITH A 14RF TYPE PROPELLER GLAND SPRING SUPPLIED. THE 14RF GLAND SPRING IS OF A SMALLER DIAMETER WHEN COMPARED TO THE 14SF GLAND SPRING. UNAPPROVED PART. PERSONNEL/MAINTENANCE ERROR.

AUS20040408

DHAV

PWA  

HAMSTD

SEAL

INCORRECT

5/16/2004

DHC8315

PW123

 

8173881

PROPELLER BLADE

(AUS) LT PROPELLER NR 4 BLADE SEAL FAILED. INSPECTION OF THE REMOVED SEAL REVEALED THE SEAL TO BE A SEAL FOR A 14SF TYPE PROPELLER WITH A 14RF TYPE PROPELLER GLAND SPRING SUPPLIED. THE 14RF GLANDSPRING IS OF A SMALLER DIAMETER WHEN COMPARED TO THE 14SF GLAND SPRING. UNAPPROVED PART. PERSONNEL/MAINTENANCE ERROR.

AUS20040409

DHAV

PWA  

 

WIRE

WORN

4/27/2004

DHC8315

PW123

 

 

OIL PRESS IND

(AUS) NR 2 ENGINE LOW OIL PRESSURE WARNING LIGHT SWITCH WIRE CHAFED AND SHORT CIRCUITING TO GROUND.

AUS20040406

DHAV

PWA  

 

VALVE

FAILED

4/23/2004

DHC8315

PW123

 

DSC1896

HYD SYSTEM

(AUS) NR 2 HYDRAULIC SYSTEM CHECK VALVE FAILED. LOSS OF HYDRAULIC FLUID. INVESTIGATION FOUND THE CHECK VALVE HAD SUFFERED METAL FATIGUE FAILURE OF THE VALVE BODY WITH THE BODY CRACKING FULLY AROUND THE CIRCUMFERENCE OF THE VALVE BODY.

2004FA0000601

DIAMON

LYC  

 

TEE FITTING

DAMAGED

7/27/2004

DA40

IO360LYC*

 

 

ENGINE SERVO

DURING MANEUVERS, THE FUEL PRESSURE GAUGE AND ENUNCIATOR SYSTEM WARN OF A LOW FUEL PRESSURE PROBLEM. ALL ENGINE INDICATIONS HOWEVER, SHOW THAT FUEL FLOW AND PRESSURE ARE NORMAL. THIS PROBLEM HAS BEEN EVIDENT IN OTHER AIRCRAFT IN THE FLEET OF 10 DA40 AIRCRAFT. THE MOST SUCCESSFUL METHOD OF ELIMINATING THIS INDICATION PROBLEM IS TO BLEED THE AIR THAT SEEMS TO HAVE ACCUMULATED IN THE TRANSDUCER LINES AND FITTINGS.

CA040708011

DOUG

PWA  

 

SEAL

FAILED

7/5/2004

A26*

R280079

 

28151

CYLINDER

(CAN) NR 1 ENGINE WAS RUNNING ROUGH AT CLIMB POWER ABOUT FOUR MINUTES AFTER TAKE OFF, THE ENGINE CONTINUED TO RUN ROUGH AT REDUCED POWER. THE PILOT SHUT DOWN THE ENGINEAND SECURED IT AND RETURNED TO BASE WITHOUT INCIDENT. MAINTENANCE FOUND TRACES OF OIL IN THE INTAKES AND THE CYLINDERS WHICH POINTS TO THE BLOWER SEAL. ENGINE CHANGE SCHEDULED.

CA040519012

DOUG

PWA  

 

VALVE

LEAKING

5/8/2004

A26BSHIELDS

R280079

 

 

PROPELLER

(CAN) ON A TRAINING FLIGHT THE RT ENGINE WAS SHUT DOWN. DURING THE RESTART, THE RT PROP BEGAN TO OVERSPEED. THE CREW ACCOMPLISHED THE OVERSPEED PROCEDURE AND RETURNED TO BASE WITHOUT INCIDENT. MAINTENANCE FOUND IN TROUBLESHOOTING THE DISTRIBUTOR VALVE HAD OIL LEAK.

CA040607002

DOUG

PWA  

 

NUT  

LOOSE

6/4/2004

B26C

CA18

 

 

PUSHROD TUBE

(CAN) PILOT NOTICED OIL LEAK AND DID A PRECAUTIONARY ENGINE SHUT DOWN. HE DID A ONE ENGINE OUT LANDING PROCEDURE AT AIRPORT WITHOUT INCIDENT. MAINTENANCE FOUND NR 17 CYLINDER PUSHROD TUBE NUT LOOSE. THE SEAL WAS REPLACED AND THE NUT TORQUED. THE ENGINE WAS GROUND RUN WITH NO EVIDENCE OF AN OIL LEAK.

CA040412008

DOUG

PWA  

 

GASKET

LEAKING

4/10/2004

C54  

R20007M2

 

 

ENGINE OIL LINE

(CAN) DURING CRUISE THE CREW NOTICED AN OIL LEAK ON THE NR 2 ENGINE. THE ENGINE WAS SHUT DOWN AND PROPELLER FEATHERED. ON INSPECTION IT WAS NOTICED THAT THE OIL PRESSURE LINE GASKET HAD BLOWN OUT. THE GASKET WAS REPLACED AND THE AIRCRAFT RETURNED TO SERVICE.

CA040416003

DOUG

PWA  

 

CYLINDER HEAD

SEPARATED

4/16/2004

C54A

R20007M2

 

153072

ENGINE

(CAN) DURING CRUISE, THE CREW NOTICE A SLIGHT VIBRATION TO THE NR 1 ENGINE, THEY ALSO NOTICED AN OIL LEAK. THE ENGINE WAS SHUT DOWN AND PROPELLER FEATHERED. DURING INSPECTION IT WAS NOTICED THAT THE NR 9 CYLINDER HEAD WAS SEPARATING FROM THE BARREL, THE ENGINE WILL BE REPLACED FOR COMPANY CONVIENCE.

CA040412009

DOUG

PWA  

 

GOVERNOR

OUT OF RIG

4/7/2004

C54ADC

R20007M2

 

R20007M2

PROPELLER

(CAN) DURING TAKE-OFF THE NR 3 ENGINE ENCOUNTERED AN OVERSPEED. THE AIRCRAFT RETURNED TO THE HANGER. IT WAS FOUND THAT THE PROP GOVENOR WAS OUT OF RIG. IT WAS RE-RIGGED AND THE AIRCRAFT WAS RETURNED TO SERVICE.

CA040712008

DOUG

PWA  

 

CYLINDER

CRACKED

7/11/2004

DC6B

CB3  

 

356995

EXHAUST

(CAN) DURING CLIMB AFTER A RETARDANT DROP ON A FIRE, NR 3 ENGINE BMEP BECAME ERRATIC AND A THUMPING WAS FELT AND BACKFIRE HEARD. THE REMAINING RETARDANT LOAD WAS JETTISONED AND THE NR 3 ENGINE WEAS SHUT DOWN AND THE PROPELLER WAS FEATHERED. THE AIRCRAFT RETURNED TO BASE. DURING INVESTIGATION BY THE MAINTENANCE CREW, IT WAS DISCOVERED THAT NR 14 CYLINDER EXHAUST EAR WAS CRACKED. THE CYLINDER WAS REPLACED, ENGINE WAS GROUND RUN AND THE AIRCRAFT WAS RETURNED TO SERVICE.

CA040602009

DOUG

PWA  

 

CYLINDER

CRACKED

5/30/2003

DC6B

CB3  

 

356995

ENGINE

(CAN) DURING DESCENT, NR 2 ENGINE BACKFIRED, THE FLIGHT CREW MOVED THE MIXTURE TO RICH, THE ENGINE STABILIZED FOR 2 MINUTES. THE ENGINE BACKFIRED AGAIN AND THE ENGINE WAS SHUT DOWN AND THE PROPELLER WAS FEATHERED. THE AIRCRAFT LANDED WITHOUT INCIDENT. UPON INVESTIGATION BY MAINTENANCE IT WAS NOTED THAT THE EXHAUST EAR ON CYLINDER NR 18 WAS CRACKED. THE CYLINDER WAS REPLACED, THE ENGINE WAS GROUND RUN AND THE AIRCRAFT WAS RETURNED TO SERVICE.

CA040712007

DOUG

PWA  

 

START VALVE

MALFUNCTIONED

7/7/2004

DC983

JT8D219

 

980109000

RT STARTER

(CAN) RT START VALVE OPEN ANNUNCIATOR LIGHT CAME ON DURING TAKE OFF ROLL. TAKE OFF REJECTED AND AIRCRAFT BACK TO THE GATE. AIRCRAFT HAS BEEN DISPATCHED IAW MEL 80-1. START VALVE HAS BEEN REPLACED ON JULY09/04.

CA040604001

DOUG

PWA  

 

INLET GUIDE VANE

OUT OF LIMITS

6/1/2004

DC983

JT8D219

 

 

NR 2 ENGINE

(CAN) CRACK FOUND ON ONE ENGINE INLET GUIDE VANE APROX 3.5 IN LONG (OUT OF LIMITS IAW MM 72-00-00). AIRCRAFT WAS FERRIED, IAW FLIGHT PERMIT AUTHORIZATION AND THE MANUFACTURER APPROVAL, ENGINE NR 2 HAS BEEN REPLACED.

CA040419004

DOUG

PWA  

 

ENGINE

FAILED

4/17/2004

DC983

JT8D219

 

 

LEFT 

(CAN) DEPARTING, WHILE CRUISING AT 31 000 FT, LOUD BANG COMING FROM LT ENGINE WITH DECREASING EPR , INCREASING EGT UP TO 575 C. DID NOT HAVE A RE-LIGHT WITH IGNITER ON INCREASING POWER WAS NOT RESPONDING, SO WE TREATED THAT AS A SEVERE DAMAGE OR SEPARATION AND THE ENGINE WAS SHUT DOWN. AIRCRAFT WAS DIVERTED.

CA040526002

DOUG

PWA  

 

CSD  

FAILED

5/22/2004

DC983

JT8D219

 

696233B

LT GENERATOR

(CAN) COMPLETE POWER INTERRUPTION ON TAKE OFF ROLL COMPLETED INTERRUPTION DURING 1 TO 3 SEC. WAS CAUSED BY RELAY DURING POWER TRANSFER. AIRCRAFT CAME BACK TO THE GATE. MAINTENANCE FOUND LT GENERATOR FREQUENCY TO LOW. AIRCRAFT WAS DISPATCHED AS IAW MEL 24-1. THE LT GENERATOR WAS REPLACED THE DAY AFTER.

CA040526003

DOUG

PWA  

 

CSD  

OVERHEATED

5/22/2004

DC983

JT8D219

 

696233B

RIGHT

(CAN) RT CSD OIL TEMPERATURE HIGH DURING CRUISE. CSD DISCONNECTED AND AIRCRAFT DIVERTED. BECAUSE THE LT GENERATOR WAS INOPERATIVE (ACFT DISPATCHED IAW MEL 24-1). RT CSD , GENERATOR AND CSD OIL COOLER WERE REPLACED AND AIRCRAFT DISPATCHED SERVICEABLE.

ANCF200400027

DOUG

PWA  

 

INDICATOR

FAILED

8/12/2004

MD83

JT8D219

 

4067241863

RATE OF CLIMB

AFTER T/O THE LT RATE OF CLIMB IND FAIL. IAW AMM 34-14-01/201 THE VERTICAL SPEED INDICATOR LT POS. WAS REMOVED AND REPLACED. OPS CHECKED ON GROUND, SATISFACTORY.

CA040602001

EMB  

ALLSN

ALLSN

BLADE

FAILED

6/2/2004

EMB135ER

AE3007A

 

 

TURBINE ROTOR

(CAN) AC YAW AND LOUD BANG IN CLIMB AT 21,000 FT. ENGINE SHUTDOWN UNCOMMANDED. EMERGENCY DECLARED AND AC DIVERTED. ON GROUND INSP FOUND THAT N1 WOULD NOT ROTATE. DISASSEMBLY OF ENG AT RRC SHOWED SEVERE TURBINE DAMAGE. SULPHIDATION, PROBABLY CAUSED THE DETERIORATION OF THE HPT 1 AND 2 NGVS. A SECTION OF THE HPT 2 NGV BROKE AND WENT INTO THE HPT 2BLADES WHICH CAUSED A BLADE FAILURE. ALL THE HPT 2 BLADES BROKE AT THE ROOT AND CAUSED THE FOD DAMAGE TO THE LPT MODULE. THIS SITUATION CAUSED THE IFSD. WHEN WE RECEIVED THE ENGINE, THE HPT MODULE WOU LD NOT TURN AND THE LPT MODULE WAS VERY DIFFICULT TO ROTATE. MFG IS EVALUATING IF THE ENGINE WILL BE REBUILT DUE TO THE EXTENSIVE TURBINE DAMAGE.

CA040602003

EMB  

ALLSN

 

SHAFT

FAILED

6/2/2004

EMB145

AE3007A

 

23056789

BEVEL GEAR

(CAN) IN CLIMB AT 8000 FT A LOUD BANG WAS HEARD AND UNCOMMANDED ENGINE SHUTDOWN AND AIR RETURN AND UNEVENTFUL LANDING OCCURRED. DISASSEMBLY OF THE ENGINE AT RRC REVEALED THAT NR 6 BEARING BEVEL DRIVING GEAR SYSTEM THAT DRIVE MODULE 05 ACCESSORY GEARBOX HAS FAILED. BEVEL GEAR HAS BROKEN IN PIECES AND HOLED THE FRONT FRAME, THE FRONT FRAME IS SCRAP. SUSPECT BEVEL DRIVE SHAFT DRIVING GEARBOX IS CAUSING THE FAILURE. SHAFT RETURNED TO INDY FOR INVESTIGATION. 2ND CASE FOR RRC OF SAME OCCURANCE REFER TO SDR 20040602002.

CA040602002

EMB  

ALLSN

 

BEVEL GEAR

FAILED

6/2/2004

EMB145XR

AE3007A

 

23056789

ACCESSORY G/B

(CAN) FLIGHT LOST POWER NOTICED SHORTLY AFTER TAKE OFF. NR 2 INDICATION WENT TO ZERO. THE CREW REPORTED THE NR 1 ENGINE SHUT DOWN IN FLIGHT. THE SHUT DOWN WAS UNCOMMANDED. THE AIRCRAFT RETURNED AND LANDED WITHOUT FURTHER INCIDENT. DISASSEMBLY OF THE ENGINE AT RRC REVEALED THAT NR 6 BEARING BEVEL DRIVING GEAR SYSTEM THAT DRIVE MODULE 05 ACCESSORY GEARBOX HAS FAILED. BEVEL GEAR HAS BROKEN IN PIECES. SUSPECT BEVEL DRIVE SHAFT DRIVING GEARBOX IS CAUSING THE FAILURE. SHAFT RETURNED TO INDY FOR INVESTIGATION.

CA040602006

EMB  

ALLSN

 

BOLT

LOOSE

6/2/2004

EMB145XR

AE3007A

 

MS955608

MANIFOLD

(CAN) COMMANDED IFSD AND AIR RETURN. CREW REPORTED EMERGENCY WHEN ITT EXCEEDED 950C. UNEVENTFUL AIR RETURN. DISASSEMBLY OF ENGINE AT RRC SHOWED THAT OUTER MANIFOLD SERVICE ATTACHMENT BOLTS LOOSEN. BLEED AIR LEAKAGE CAUSED THERMAL DAMAGE TO THE SURROUNDING COMPOSITE STRUCTURE OF THE OUTER BYPASS DUCT. REDUCE COOLING AIR TO THE TURBINE HAS INCREASE THE ITT. SERVICE BULLETIN 75-025 INTRODUCE A MODIFIED RETAINING BOLT WHICH INCLUDE A LOCKING WIRE HOLE TO PREVENT BOLT TO LOOSEN AND SB 75-026 INTRODUCE A SAFETY WIRE. REAR BYPASS DUCT REPLACED AN SB INCORPORATED. BOTH SB ARE OPTIONAL CATEGORY.

CA040625007

EMB  

ALLSN

 

ENGINE

FAILED

6/23/2004

EMB145XR

AE3007A

 

 

NR 2 

(CAN) PRELIMINARY REPORT THE CREW REPORTED THAT ON DESCENT, THE NR 2 ENGINE FAILED (UNCOMMANDED SHUT DOWN). THE AIRCRAFT LANDED WITHOUT INCIDENT. ON GROUND, THE FAN WOULD NOT ROTATE FREELY, BUT CORE COULD NOT BE ROTATED VIA PMA SHAFT. ENGINE ALLOCATED TO RRC, FURTHER DETAIL WILL BE SUBMITTED AFTER ENGINE STRIP.

AUS20040450

FOKKER

PWA  

 

WIRE HARNESS

BROKEN

5/27/2004

F27MK50

PW125B

 

F7941116401

ANTISKID SYS

(AUS) LT IB WHEEL SPEED SENSOR WIRE BROKEN. RB IB TYRE BLOWNOUT.

AUS20040381

FOKKER

RROYCE

 

STRINGER

CRACKED

5/7/2004

F28MK0100

TAY65015

 

STRINGER68

FUSELAGE

(AUS) STRINGER 68 CRACKED.

AUS20040370

FOKKER

RROYCE

 

TANK

CORRODED

5/10/2004

F28MK0100

TAY65015

 

 

FUEL STORAGE

(AUS) RT WING FUEL SYSTEM COLLECTOR TANK CONTAINED LEVEL 3 CORROSION ON LOWER INTERNAL SURFACE.

AUS20040371

FOKKER

RROYCE

 

TANK

CORRODED

5/10/2004

F28MK0100

TAY65015

 

 

FUEL STORAGE

(AUS) LT WING FUEL SYSTEM COLLECTOR TANK CONTAINED LEVEL 3 CORROSION ON LOWER INTERNAL SURFACE.

AUS20040354

FOKKER

RROYCE

 

SKIN

CORRODED

5/6/2004

F28MK0100

TAY65015

 

 

WING 

(AUS) RT WING TIP TRAILING EDGE CORRODED. CORROSION ALSO FOUND UNDERSTATIC DISCHARGER BASE.

AUS20040355

FOKKER

RROYCE

 

STRINGER

CORRODED

5/6/2004

F28MK0100

TAY65015

 

 

CENTER WING

(AUS) WING CENTER SECTION EXTERNAL LOWER SURFACE Z SECTION STRINGERS CONTAINED LEVEL 3 CORROSION.

AUS20040356

FOKKER

RROYCE

 

BRACKET

CORRODED

5/6/2004

F28MK0100

TAY65015

 

D18016

AILERON TAB

(AUS) AILERON TAB BEARING BRACKET CONTAINED LEVEL 3 CORROSION.

AUS20040346

FOKKER

RROYCE

 

SKIN

CORRODED

5/6/2004

F28MK0100

TAY65015

 

 

WING 

(AUS) WING TRAILING EDGE CONTAINED CORROSION ON BOTH SIDES.

AUS20040347

FOKKER

RROYCE

 

FLOORBEAM

CORRODED

5/6/2004

F28MK0100

TAY65015

 

 

FUSELAGE

(AUS) CABIN FLOOR PANEL SUPPORT BEAMS (2OFF) CORRODED. SUSPECT CAUSED BY INCORRECT REMOVAL OF FLOOR PANEL AND GAP SEALANT USING A SHARP EDGED TOOL WHICH SCORED THE BEAMS. CORROSION INITIATED AT THE SCORE MARKS. PERSONNEL/MAINTENANCE ERROR.

AUS20040348

FOKKER

RROYCE

 

STRINGER

CORRODED

5/6/2004

F28MK0100

TAY65015

 

 

FUSELAGE

(AUS) CENTER CARGO COMPARTMENT CORRODED ON FORWARD FACE OF DOOR SILL BEAM AND LOWER SHELL STRINGERS.

CA040623001

FOUND

LYC  

 

NUT  

LOOSE

6/21/2004

FBA2C

IO540D4A5

 

AN316

CONTROL CABLE

(CAN) DURING A ROUTINE INSPECTION THE JAM NUTS THAT SECURE THE PROP CONTROL CABLE TO AN ATTACHMENT BRACKET AT THE PROP GOVERNOR WERE FOUND LOOSE. THE LOWER JAM NUT HAD BACKED OFF COMPLETELY AND THE CABLE WAS FREE TO MOVE, BUT IN ONE DIRECTION ONLY. THE CONTROL CABLE IS SECURED TO THE ATTACHMENT BRACKET WITH JAM NUTS THAT ARE SECURED WITH INTERNAL TOOTH LOCKWASHERS, BUT DO NOT HAVE HOLES FOR SECURING WITH LOCKWIRE.

CA040715006

GRUMAN

WRIGHT

 

BOLT

BROKEN

7/15/2004

TS2ACALFORST

982C9HE2

 

65678

ROCKER ARM

(CAN) DURING INSPECTION, AN OIL LEAK WAS DISCOVERED ON THE RT ENGINE CYLINDER POSITION NR 2. UPON INVESTIGATION AND RECTIFICATION, THE MAINTENANCE CREW WAS ATTEMPTING TO REPLACE THE O-RINGS ON THE EXHAUST ROCKER ARM RETAINING BOLT. THE RETAINING NUT AND COTTER PIN CAME OFF AS A COMPLETE UNIT. IT WAS NOTED THAT THE BOLT HAD SHEARED AT THE FIRST ROW OF THREADS. THE BOLT WAS REPLACED AND THE AIRCRAFT WAS RETURNED TO SERVICE.

CA040604014

GULSTM

GARRTT

 

VALVE

FLUCTUATES

6/3/2004

690  

TPE3315251K

 

8953804

HP LIMITER

(CAN) DURING CLIMB OUT THROUGH 5000 FEET, ENGINE POWER BEGAN TO FLUCTUATE. ENGINE WAS SHUTDOWN AND SECURED. AIRCRAFT LANDED WITHOUT INCIDENT. INVESTIGATION FOUND THAT THE HORSE POWER LIMITER BYPASS VALVE WAS LEAKING INTERNALLY. BYPASS VALVE WAS REPLACED.

AUS20040413

HUGHES

LYC  

 

BOLT

SEPARATED

5/14/2004

269C

HIO360D1A

 

NAS130310D

FUEL CONTROL

(AUS) GOVERNOR LINKAGE BOLT SEPARATED. LOSS OF ENGINE CONTROL RESULTED IN AUTO ROTATION AND HEAVY LANDING WITH SOME MINOR DAMAGE TO THE AIRCRAFT.

CA040413004

HUGHES

ALLSN

 

BLADE

DAMAGED

8/13/2003

369D

250C20B

 

 

MAIN ROTOR

(CAN) PIN FAILURE, SHEARED AT TOP THREAD OF THREADED SHANK FOR ADJUSTER NUT.

CA040503004

LEAR

GARRTT

 

WHEEL

CRACKED

2/13/2003

35LEAR

TFE73122B

 

95440263

MLG 

(CAN) DURING ROUTINE TIRE CHANGE, NDT REVEALED SEVERAL CRACKS AROUND THE FLANGE IN THE AREAS WHERE THE BRAKE ASSEMBLY SLIDES INTO THE WHEEL HALF. WHEEL HALF REMOVED FROM SERVICE.

CA040713003

LEAR

GARRTT

 

TIRE

CUT  

6/5/2004

35LEAR

TFE73122B

 

173K233

MLG 

(CAN) DURING DAILY INSPECTION, FOUND NR 2 MLG WHEEL TIRE CUT. THE CUT WAS LOCATED ON THE SIDE WALL. WHEEL ASSEMBLY REPLACED.

AUS20040416

LEAR

GARRTT

 

ACTUATOR

LEAKING

5/19/2004

45LEAR

TFE731*

 

6627602001005

DRAG CONTROL

(AUS) LT WING SPOILER ACTUATOR PRESSURE SWIVEL FAILED. LOSS OFHYDRAULIC FLUID.

AUS20040375

LEAR

GARRTT

 

ACTUATOR

DAMAGED

5/5/2004

45LEAR

TFE7312

 

6632303003001

MLG DOOR

(AUS) LT MAIN LANDING GEAR IB DOOR ACTUATOR DAMAGED. ACTUATOR HOUSING END CAP SEPARATED FROM HOUSING DUE TO SHEARING OF THE FOUR END CAP BOLT HEADS. LOSS OF HYDRAULIC FLUID.

AUS20040321

PARTEN

LYC  

 

SUPPORT ANGLE

CRACKED

5/1/2004

P68B

IO360A1B6

 

AV50903

WING SPAR

(AUS) WING SPAR STRAP SUPPORT FORWARD AND AFT ANGLES CRACKED ALONG RIVET LINE.

CA040323002

PILATS

PWA  

 

PUMP

CRACKED

3/18/2004

PC1245

PT6A67B

 

9603001153

HYD SYSTEM

(CAN) AIRCRAFT WAS ON DECENT. WHEN GEAR DOWN WAS SELECTED DOWN GRINDING NOISES WERE HEARD IN THE CABIN AND THE NOSE DOWN AND LOCKED LIGHT WAS NOT ILLUMINATED. EMERGENCY PROCEDURES WERE USED TO GET THE NOSE DOWN LOCKED LIGHT AND THE A/C WAS LANDED WITHOUT FURTHER INCIDENT. HYDRAULIC FLUID WSA NOTICED LEAKING IN THE POWER PACK AREA. THE A/C WAS FERRIED. ON CHANGING THE POWER PACK A CRACK WAS DISCOVERED ON THE PUMP BODY ON THE OPPOSITE END FROM THE MOTOR.

CA040713009

PILATS

PWA  

 

EXHAUST STACK

CRACKED

7/12/2004

PC1245

PT6A67B

 

5781012041

LT ENGINE

(CAN) LT EXHAUST STACK CRACKED FROM ONE MOUNTING HOLE OUTWARDS. STACK REPLACED WITH SERVICEABLE UNIT. CRACK DISCOVERED DURING ENGINE INSPECTION.

CA040713010

PILATS

PWA  

 

SWITCH

INTERMITTENT

7/12/2004

PC1245

PT6A67B

 

9736142510

EXTERIOR LIGHTS

(CAN) WHILE PERFORMING DAILY INSPECTION AND REPORTED INTERMITTENTLY BY PILOT THAT TWO LIGHT SWITCHES ON CONTROL PANEL. OCCASIONALLY WILL NOT SWITCH (OFF) OR SOMETIMES WILL NOT REMAIN IN (ON) POSITION THIS WOULD OCCUR INTERMITTENTLY AND IT WAS DISCOVERED. PROBLEM IS AN INTERNAL MALFUNCTION. THIS OCCURRED ON (STROBE/BEACON) SWITCH AND (TAXI/LOGO) LIGHT SWITCH. BOTH SWITCHES ARE THE SAME PN. SWITCHES REPLACED WITH NEW.

CA040709008

PILATS

PWA  

BFGOODRICH

WARNING FLAG

MALFUNCTIONED

7/8/2004

PC1245

PT6A67B

 

 

STBY ATTITUDE IN

(CAN) (OFF) WARNING FLAG DOES NOT COMPLETELY GO OUT OF VIEW. GYRO WAS FUNCTIONING NORMALLY AND FLAG SEEMS TO BE DISLOCATED TOO FAR TO THE RIGHT AS COMPARED TO A SERVICEABLE UNIT.

CA040712006

PILATS

PWA  

 

VALVE

FAILED

7/10/2004

PC1245

PT6A67B

 

9599020135

TEMP CONTROL

(CAN) TEMP CONTROL VALVE FOUND TO BE AT FAULT AFTER CREW COMPLAINED OF ECS HEAT NOT RESPONSIVE. VALVE REPLACED WITH REPAIRED UNIT, RETURNED TO SERVICE.

CA040604003

PILATS

PWA  

 

SEAL

DAMAGED

6/3/2004

PC1245

PT6A67B

 

3022376

EPA CAN

(CAN) AIRCRAFT HAD JUST LANDED AND SHUT DOWN AT IT'S DESTINATION AIRPORT. THE PILOT DISEMBARKED THE AIRCRAFT AND NOTICED A LARGE STREAK OF OIL DOWN THE LT SIDE OF THE FUSELAGE. MAINTENANCE INVESTIGATED THE INCIDENT AND FOUND ANOTHER LARGE OIL STREAK DOWN THE BELLY OF THE AIRCRAFT. IN ADDITION TO THE TWO OIL STREAKS THE EPA CAN WAS COMPLETELY FULL. THE STARTER-GENERATOR WAS REMOVED, AND MAINTENANCE FOUND THE OIL SEAL WAS SLIGHTLY DAMAGED. A NEW SEAL WAS INSTALLED AND THE AIRCRAFT GROUND RUN WITH NO FURTHER DEFECTS NOTED.

CA040709009

PILATS

PWA  

 

PDU  

FAILED

6/29/2004

PC1245

PT6A67B

 

9787320003

TE FLAPS

(CAN) FLAPS WERE SELECTED UP, RETRACTED NORMALLY. FLAPS WERE SELECTED DOWN, EXTENDED NORMALLY. FLAPS WERE RETRACTED ONCE MORE, OPS WERE NORMAL. FLAPS WERE SELECTED DOWN, WHEN THEY REACHED 15 DEGREE POINT, STARTED TO BIND AND FLAP RESET WAS PERFORMED. FLAPS WERE SELECTED TO 30 DEGREES. FLAPS OPERATED, BUT CUT IN AND OUT. FLAPS WERE SELECTED TO 40 DEGREES, OPERATED NORMALLY. WHEN SELECTED DOWN, STARTED TO BIND BETWEEN 15 DEGREES, 30 DEGREES, RCCB POPPED. BINDING NOISE CAME FROM RT FLAP. FLOOR ACCESS PANEL TO FLAP PWR DRIVE UNIT WAS REMOVED. FLAP PWR DRIVE UNIT WAS HOT AND THERE WAS STRONG ELECTRICAL SMELL FROM PDU. FLAP PWR DRIVE UNIT WAS REPLACED, FLAPS OPERATED NORMAL.

CA040709010

PIPER

LYC  

 

INDICATOR

INOPERATIVE

6/14/2004

PA23250

IO540C4B5

 

1766903

TE FLAPS

(CAN) LANDING GEAR LIGHTS WOULD NOT WORK. NOTICED FLAP INDICATOR DARK IN COLOR. DISCONNECTED WIRE FROM THE FLAP INDICATOR AND GEAR LIGHTS WORKED. REPLACED INDICATOR AND SYSTEM WORKED NORMAL.

CA040709004

PIPER

LYC  

 

WIRE

CUT  

6/26/2004

PA23250

IO540C4B5

 

 

CHT PROBE

(CAN) IN FLIGHT, THE PILOT NOTICED THAT THE LT ENGINE CYLINCER TEMPERATURE WAS ABNORMALLY HIGH. ALL OTHER PARAMETERS WERE IN THE GREEN. THE PILOT ASKED FOR A PRIORITY LANDING. WE DISCOVERED THAT THE WIRING FOR THE CHT PROBE WAS CUT. THE TERMINAL WAS REPLACED, EVERYTHING BACK TO NORMAL.

CA040713002

PIPER

LYC  

 

EXHAUST STACK

CRACKED

6/30/2004

PA28140

O320E3D

 

99044004

ENGINE

(CAN) UNDISTINGUISHABLE ODOR OF SOMETHING BURNING, FOLLOWED BY STIFF CARB HEAT CABLE AND ENGINE RUNNING ROUGH WITH CARB HEAT APPLICATION. THE RT EXHAUST STACK HAD CRACKED, HIDDEN BY THE CARBURETOR HEAT SHROUD. DURING FLIGHT, THE HEAT FROM THE EXHAUST BEING EXPELLED FROM THE CRACKED STACK, MELTED THE TOP OF THE CARB HEAT SHROUD (APPROXIMATELY .5000 INCH WIDE AND 4 INCHES LONG). THE EXHAUST ESCAPING FROM THE CARB HEAT SHROUD BLISTERED THE PAINT ON THE FIREWALL, MELTED THE CARB HEAT CABLE GROMMET LOCATED ON THE FIREWALL AND RENDERED THE CARB HEAT CABLE INOPERATIVE IN THE CLOSED POSITION.

AUS20040425

PIPER

LYC  

 

ROD END

FAILED

5/23/2004

PA31325

TIO540F2BD

 

762554

MLG ACTUATOR

(AUS) LT MAIN LANDING GEAR ACTUATOR ROD END FAILED. AIRCRAFT LANDED WITH LT MAIN LANDING GEAR FULLY RETRACTED.

CA040413012

PIPER

LYC  

 

SEAL

LEAKING

4/12/2004

PA31350

LTIO540J2BD

 

 

VACUUM PUMP

(CAN) AT 400 HRS SPECIAL INSPECTION FOUND OIL LEAK ON RT ENGINE, OUT OF VACUUM PUMP SHAFT. REMOVED PUMP FOUND DRIVE SHAFT SEAL LEAKING PN: 06A19956. AFTER THE SEAL REMOVAL DURING VISUAL INSPECTION FOUND RUBBER PART OF THE SEAL SCUFFED IN SOME PLACES CAUSING THE LEAKAGE.

CA040416002

PIPER

LYC  

 

SUPPORT

CRACKED

4/16/2004

PA31350

LTIO540J2BD

 

LW18302

TURBOCHARGER

(CAN) TURBOCHARGER SUPPORT MOUNT FOUND CRACKED ON LOWER LT TUBE.

CA040416001

PIPER

LYC  

 

TRUNNION

CRACKED

4/8/2004

PA31350

TIO540J2BD

 

4032700

MLG 

(CAN) ON LANDING, THE AIRCRAFT SLOWLY SETTLED WITH THE LT WING LOW ON LANDING ROLL. THE PILOT STOPPED AND SHUT DOWN THE ENGINES. THE PILOT CALLED MAINTENANCE AND MAINTENANCE INSPECTED THE AIRCRAFT ON THE RUNWAY. THE AME NOTICED A LOT OF HYDRAULIC FLUID ON THE GEAR LEG AND FOUND THE CRACK IN THE HOUSING. THE AIRCRAFT WAS TOWED TO THE HANGER. THE HOUSING WAS REPLACED WITH A NEW UNIT AND THE AIRCRAFT WAS RETURNED TO SERVICE.

CA040414002

PIPER

LYC  

 

SKIN

CRACKED

4/14/2004

PA31350

TIO540J2BD

 

4065910

RT WING

(CAN) CRACKING OF RT WING LEADING EDGE SKIN AT STA 160.50 AND 174.50 FROM RIVETS 1 RIVET FORWARD OF STRINGER AHEAD OF THE SPAR. REVIEW OF AIRCRAFT RECORDS DID NOT SHOW ANY RECENT HISTORY OF HARD LANDINGS.

CA040714001

PIPER

LYC  

 

PUMP

LEAKING

7/7/2004

PA31350

TIO540J2BD

 

RG9080J4AM

ENGINE FUEL

(CAN) DURING SCHEDULED MAINTENANCE THE FUEL PUMP WAS NOTED AS LEAKING FUEL. THIS PUMP IS NOT COVERED BY THE AD 2003-14-03 AS IT IS MODIFIED. PUMP REPLACED BEFORE FURTHER FLIGHT.

CA040625008

PIPER

LYC  

 

DRIVE SHAFT

SHEARED

6/24/2004

PA31350

TIO540J2BD

 

441CC7

VACUUM PUMP

(CAN) ON LT ENGINE WARMING UP, FOUND LIGHT WARNING INDICATION (ON) IN RANGE OF RPM . WHILE TROUBLESHOOTING FOUND LT VACUUM PUMP DRIVE SHAFT SHEARED. NO OTHER DAMAGE FOUND AT VISUAL INSPECTION.

CA040624003

PIPER

LYC  

 

INJECTOR

MALFUNCTIONED

6/17/2004

PA31350

TIO540J2BD

 

25245009

ENGINE

(CAN) ENGINE EXPERIENCED POWER LOSS. MANIFOLD PRESSURE WENT FROM 32 - 20 INCHES. FLIGHT CREW MADE UNSCHEDULED LANDING WITHOUT INCIDENT. ENGINEER FOUND THAT SERVO FUEL INJECTOR WAS THE PROBLEM AND HAD FLOODED OUT THE ENGINE. ENGINEER REPLACED SERVO FUEL INJECTOR WITH SERVICEABLE UNIT. RAN UP A/C ALL CHECKED OUT AND A/C RETURNED WITHOUT FURTHER PROBLEMS. A/C HAS BEEN FLYING SERVICEABLE SINCE THEN.

AUS20040393

PIPER

LYC  

 

GEAR

FAULTY

5/11/2004

PA31350

TIO540J2BD

 

10682014

MAGNETO

(AUS) MAGNETO DISTRIBUTOR GEAR FINGER INCORRECTLY FITTED. FINGER WAS LOCATED APPROXIMATELY 180 DEGREES FROM LOCATING LUGS.

AUS20040369

PIPER

LYC  

 

ENGINE

MAKING METAL

5/3/2004

PA31350

TIO540J2BD

 

L421861A

LEFT 

(AUS) LT ENGINE METAL CONTAMINATION. METAL PARTICLES IN FILTER WERE NON-FERROUS FLAKES WITH THE LARGEST FLAKES APPROXIMATELY 6MM BY 4MM (0.236IN BY 0.157IN). SUSPECT BEARING MATERIAL.

CA040520004

PIPER

PWA  

 

BULKHEAD

CRACKED

5/20/2004

PA31T

PT6A28

 

50090XX

BEHIND FIREWALL

(CAN) MAINTENANCE INSPECTION REVEALED CRACKING IN THE LONGITUDINAL BULKHEADS (BOTH) BEHIND EACH ENGINE. THESE BULKHEADS RUN THE LENGTH OF THE NACELLE, FROM THE FIREWALL TO THE TRAILING EDGE OF THE NACELLE. THE CRACKS ARE PRESENT WHERE THE BULKHEADS NARROW TO ACCOMODATE THE FRONT WALL OF THE NACELLE FUEL TANK AND THE CUTOUTS FOR PLUMBING AND AIR DUCTS. PRESENTLY PURSUING A REPAIR DESIGN CERTIFICATE TO ADDRESS THIS PROBLEM.

AUS20040344

PIPER

LYC  

 

BEARING

SEIZED

5/1/2004

PA32300

IO540K1A5

 

 

MAGNETO

(AUS) MAGNETO REAR BEARING SEIZED. CONTACT BREAKERS MELTED.

AUS20040441

PIPER

LYC  

 

TRUNNION

CRACKED

5/21/2004

PA32R301

IO540K1G5

 

6792631

RT MLG

(AUS) RT MAIN LANDING GEAR TRUNNION CRACKED.

CA040609013

PIPER

LYC  

 

THROTTLE CABLE

BROKEN

5/27/2004

PA32RT300T

TIO540S1AD

 

455360

CNTRL LEVER END

(CAN) AFTER A PREFLIGHT CHECK, THE PILOT COMPLAINED OF AN EXTREMELY LOOSE THROTTLE CONTROL. AFTER FURTHER INSPECTION, THE CONTROL CABLE WAS DETERMINED TO BE INTERNALLY BROKEN. THE CABLE WAS REMOVED AND THE CONTROL LEVER END OF THE CABLE PULLED OUT OF THE EXTERNAL CASE EXPOSING THE INTERNAL CABLE STRANDS. TWO OF THESE STRANDS WERE BENT OVER SUGGESTING THEY WERE BROKEN FOR SOME TIME. PILOT HAS NEVER COMPLAINED OF A (STIFF THROTTLE CONDITION).

CA040604002

PIPER

LYC  

 

PISTON

BROKEN

5/19/2004

PA44180

O360A1H

 

75089LW11775

ENGINE

(CAN) DURING NR 1 INSP, A SIG AMOUNT OF NON-FERROUS METAL WAS FOUND IN OIL FILTER ELEMENT. OIL SUCTION SCREEN WAS PULLED AND WAS FOUND TO BE FULL OF NON-FERROUS METAL. CYL NR 1 WAS PULLED AND FWD PISTON PIN PLUG WAS FOUND TO BE WORN COMPLETELY ALLOWING PISTON PIN TO MIGRATE FWD TO POINT AFT PISTON PIN PLUG WAS ONLY PART LEFT IN AFT PISTON BOSS BETWEEN CONNECT ROD AND PISTON. AFT PISTON BOSS HAD 1 INCH PIECE BROKEN OUT OF IT. NR 3 CYL WAS REMOVED, WAS FOUND THAT FORWARD PISTON PIN PLUG WAS STARTING TO WEAR ABOUT .0625 OF AN INCH. HEAT AND TIME, ALUMINUM PLUG WORE AGAINST STEEL CYLINDER AND ONCE WEAR STARTED, IT WORE RAPIDLY. NO IND OF OIL PRESS OR POWER LOSS ON PREVIOUS FLIGHT OR DURING RUN UP FOR INSP.

CA040326006

PIPER

CONT

 

MOUNT

CRACKED

3/23/2004

PA46310P

TSIO550C

 

8401002

ENGINE

(CAN) ENGINE MOUNT CRACKED AT AREA DESCRIBED IN MFG SB NR 1103 REV.B NOTE: THIS SHOULD BE NOTIFIED TO ALL OWNERS BY AN AIRWORTHINESS DIRECTIVE.

AUS20040385

REIMS  

PWA  

 

COMPUTER

FAULTY

4/14/2004

F406

PT6A112

 

065006401

AUTOPILOT

(AUS) AUTOPILOT COMPUTER FAULTY.

AUS20040350

REIMS  

PWA  

 

STRIP

SEPARATED

4/23/2004

F406

PT6A112

 

60150301

STALL WARNING SY

(AUS) STALL STRIP MISSING.

AUS20040374

REIMS  

PWA  

 

WIRE

BROKEN

5/7/2004

F406

PT6A112

 

A157BA2579920

TE FLAPS

(AUS) FLAP CONTROL SYSTEM WIRE BROKEN. FAULT TRACE TO BROKEN WIRE A157B-A25799200 TO FLAP UP CONTROL SWITCH.

AUS20040319

ROBSIN

LYC  

 

PUMP

LEAKING

4/30/2004

R44  

IO540*

 

LW15473

ENGINE FUEL

(AUS) AIRCRAFT MOUNTED ENGINE FUEL PUMP LEAKING.

AUS20040396

ROBSIN

LYC  

 

SHIELD

SEPARATED

5/11/2004

R44  

IO540AE2A

 

D3171

EXHAUST

(AUS) EXHAUST SHIELD MISSING. ATTACHMENT TABS REMAINED ON EXHAUST ASSEMBLY.

AUS20040363

ROBSIN

LYC  

BENDIX

BEARING

FAILED

4/24/2004

R44  

O540F1B5

BL6006163

2202 

MAGNETO

(AUS) LT MAGNETO BEARING FAILED.

CA040623002

SKRSKY

PWA  

 

DUMP VALVE

MALFUNCTIONED

6/5/2004

S64E

JFTD12A4A

 

586982

ENGINE FUEL

(CAN) AS COLLECTIVE WAS LOWERED FLIGHT CREW HEARD A (WHOOSH) SOUND FOLLOWED BY AN ENG N1 UNDER-SPEED WARNING AUDIO. FLIGHT CREW VERIFIED ENG, IMMEDIATELY EXECUTED AN IN-FLIGHT SHUTDOWN OF NR 1 ENG TO PREVENT OVER-TEMP CONDITION. WITH NR 1 ENG SHUTDOWN, AC RETURNED TO ITS SERVICE AREA WITHOUT FURTHER INCIDENT. INSP OF ENG, ITS RELATED CONTROL LINKAGES REVEALED NOTHING ABNORMAL. ENG FUEL PRESSURIZING, DUMP VALVE (P&D VALVE) WAS CHANGED AS A STANDARD PROCEDURE IN A SOFT STALL OCCURRENCE. ADDITIONALLY, FCU WAS ALSO CHANGED AS PRECAUTIONARY MEASURE. ENG WAS RESTARTED, GROUND-RUN, FOUND TO BE ACCEPTABLE AC WAS RELEASED FOR FLIGHT. THE SUSPECT COMPONENTS WERE RETURNED TO MFG FOR INTERNAL INSPECTION, EVALUATION.

CA040603003

SKRSKY

PWA  

 

DUMP VALVE

MALFUNCTIONED

5/20/2004

S64E

JFTD12A4A

 

586982

ENGINE FUEL

(CAN) PILOT BEGAN DESCENT, HEARD (WHOOSH) SOUND TYPICAL OF SOFT STALLING ENG. FOLLOWE D BY N1 UNDERSPEED AUDIO, INDICATOR LIGHT WARNING. FLT CREW VERIFIED NR 1 ENG AS BEING AT FAULT. COPILOT SHUTDOWN ENG, BEGAN TO MOTOR TO DECREASE T5 TEMP WHILE PILOT RELEASED LOAD. WITH T5 TEMP STABILIZED ENG WAS SECURED, AC RETURNED TO ITS SERVICE LANDING, MADE AN UNEVENTFUL SINGLE ENG LANDING. COMPLETE VISUAL INSP OF ENG WAS CARRIED OUT BY MAINT CREW WHICH REVEALED NOTHING ABNORMAL. FUEL PRESS AND DUMP (P&D) VALVE, ENG FUEL FILTER WERE REPLACED AS IS MAINT PROCEDURE AFTER AN ENG SOFT STALL. LIMITS HAVE NOT BEEN EXCEEDED. ENG FCU WAS ALSO REPLACED. FOLLOWING ENG GROUND RUN AND TEST, AC WAS RETURNED TO SERVICE.

AUS20040334

SKRSKY

TMECA

 

FITTING

CRACKED

5/4/2004

S76C

ARRIEL1S

 

7620902019043

MLG DOOR

(AUS) LT MAIN LANDING GEAR DOOR HINGE FITTING FAILED.

CA040603002

SNIAS

TMECA

 

BOLT

FRACTURED

6/2/2004

AS332L

MAKILA1A

 

332A32323300

ENGINE MOUNT

(CAN) AFTER LAST FLIGHT, DAILY INSPECTION WAS BEING CARRIED OUT ON THE AIRCRAFT, WHEN THE NR 1 ENG LT UPPER TIE BOLT WAS FOUND TO BE FRACTURED. THE OTHER TWO TIE BOLTS WERE REMOVED AND INSPECTED AND FOUND TO BE SERVICEABLE. THIS TIE BOLT ATTACHES THE ENGINE TO THE G/B P/N 332A32-1007-03P.

CA040325004

SNIAS

TMECA

 

DRIVE ASSY

BROKEN

3/22/2004

AS350B2

ARRIEL1D1

 

704A33690004

HYD PUMP

(CAN) DURING A HOVER FLIGHT HYDRAULIC WARNING LIGHT CAME ON. THE PILOT STABILIZED THE A/C AND RETURNED TO CAMP IN MANUAL CONTROL MODE. UPON INSPECTION, AME DISCOVERED BROKEN HYDRAULIC PUMP PULLEY DRIVE BELT. BELT REPLACED, A/C RETURNED TO SERVICE.

CA040504006

SNIAS

TMECA

 

WIRE

SEVERED

4/28/2004

AS350B3

ARRIEL2B

 

LJILO38

NAVIGATION LIGHT

(CAN) ROUTINE TROUBLESHOOTING FOR INOPERATIVE NAV LIGHT STARBOARD, DISCOVERED POSITIVE WIRE WAS SEVERED FROM CRIMPED PIN BY SLIGHTLY TUGGING ON WIRES FROM THE BACKSHELL. SINCE NO ACCESS AVAILABLE TO REMOVE BROKEN OFF PIN OUT OF LAMP ASSEMBLY, A NEW ASSEMBLY HAD TO BE INSTALLED.

CA040503003

SNIAS

TMECA

 

BLADE

DAMAGED

4/15/2004

AS350BA

ARRIEL1B

 

355A11003000

MAIN ROTOR

(CAN) BLADE RETURNED FOR EVALUATION. AT STA 760 MM, AT ROOT END, AN AREA OF SKIN (150 MM LONG BY 2 MM WIDE) WAS MISSING FROM THE ROOT MATING FACE. THIS APPEARS TO BE A MANUFACTURING DEFECT AND HAS BEEN RETURNED TO THE MANUFACTURER FOR EVALUATION/REPAIR.

CA040420002

SNIAS

TMECA

 

BELT

CRACKED

3/29/2004

AS350BA

ARRIEL1B

 

704A33690004

HYDRAULIC PUMP

(CAN) WHILE DOING BULLETIN ON HYDRAULIC SYSTEM IT WAS NOTICED THAT THE BELT WAS CRACKED.

CA040604007

SNIAS

LYC  

 

MODULATOR

FAILED

5/24/2004

AS350D

LTS101600A2

 

430110209

AIRFLOW

(CAN) PILOT HEARD AND FELT LOUD POPPING NOISE FROM ENGINE ACCOMPANIED WITH LOSS OF POWER. AIRCRAFT LANDED SUCCESSFULLY. FLOW FENCE PROBLEM SUSPECTED. AIRFLOW MODULATOR REPLACED, AIRCRAFT TEST FLOWN OK.

CA040115002

SWRNGN

GARRTT

 

PLENUM

CRACKED

1/13/2004

SA226TC

TPE33110UA

 

310166812

ENGINE

(CAN) FLIGHT CREW RECEIVED SPLIT SECOND FIRE WARNING INDICATION ON LT ENG. DUE TO BRIEF NATURE OF IND FLIGHT CREW MONITORED GAUGES, DETERMINED FALSE INDICATION. SHORTLY AFTER ENG STARTED LOSING PWR UNTIL IT REACHED ABOUT 55 PERCENT TORQUE. UPON INSP, LT ENG PLENUM DRAIN FIT WAS FOUND CRACKED, PARTIALLY SEPARATED FROM ENG PLENUM IN REARWARD DIRECTION. ALLOWED HOT COMBUST GASES INTO ENG COMPART. PLENUM DRAIN FITTING IS WELDED TO ENG PLENUM. INSP REVEALED MINOR FIRE DAMAGE TO ENG WIRING HARNESS, SURROUNDING AREA. REASON FOR CRACKED FITTING WAS DETERMINED TO BE DRAIN TUBE ATTACHED TO FITTING WAS INSTALLED IN SUCH WAY IT WAS PUTTING A REARWARD LOAD ON DRAIN FITTING, CAUSING IT TO CRACK AND BREAK AWAY FROM PLENUM.

CA040415007

SWRNGN

GARRTT

 

PINION GEAR

BROKEN

4/13/2004

SA226TC

TPE33110UA

 

310117017

ENGINE

(CAN) AFTER TAKEOFF, FLIGHT CREW HAD CHIP DETECTOR LIGHT ILLUMINATE ON RT ENG. CREW REDUCED POWER AND IMMEDIATELY RETURNED TO LAND. MAINT WAS SENT TO INSPECT CHIP DETECTOR, DISCOVERED SEVERAL CHUNKS OF FERROUS METAL ON CHIP DETECTOR PLUG. OIL FILTER WAS REMOVED AND INSPECTED, FOUND TO CONTAIN AN ABNORMAL AMOUNT OF METAL. UPON ROTATING PROP, A GRINDING/RATTLING NOISE WAS OBSERVED COMING FROM GEAR CASE. ENG WAS REPLACED AND UNSERVICEABLE ENG TORN DOWN. INITIAL FINDINGS WERE THAT HIGH SPEED PINION GEAR HAD SHED A GEAR TOOTH WHICH WAS WHAT WAS FOUND ON CHIP DETECTOR. NO FURTHER REASON FOR PINION GEAR FAILURE HAS BEEN DISCOVERED. MORE INFORMATION WILL FOLLOW IF ANY CAUSE OR CONTRIBUTING FACTORS CAN BE DETERMINED.

AUS20040399

SWRNGN

GARRTT

 

PIPE

CRACKED

5/3/2004

SA227*

TPE33112UHR

 

31080811

TORQUE SENSOR

(AUS) LT ENGINE NEGATIVE TORQUE SENSOR (NTS) OIL PIPE CRACKED IN FLARE.

AUS20040403

SWRNGN

GARRTT

 

DRAG BRACE

FRACTURED

5/16/2004

SA227*

TPE33112UHR

 

OAS55015

MLG 

(AUS) RT MAIN LANDING GEAR UPPER DRAG BRACE UPLOCK LUGS FRACTURED. CAUSED BY DRAG BRACE OUT OF ADJUSTMENT.

AUS20040404

SWRNGN

GARRTT

 

ACTUATOR

LEAKING

5/16/2004

SA227AC

TFE33112UHR

 

2736053003

TE FLAPS

(AUS) RT TRAILING EDGE FLAP ACTUATOR LEAKING FLUID FROM AROUND THE ACTUATOR RAM. LOSS OF HYDRAULIC FLUID.

CA040709006

SWRNGN

GARRTT

 

WATER INJECTION

INOPERATIVE

6/28/2004

SA227AC

TPE33111U

 

 

ENGINE

(CAN) WATER METHANOL DID NOT WORK ON TAKE OFF ROLL. LT AND RT PUMP LIGHTS WERE ON. AIRCRAFT RETURNED TO GATE. MAINTENANCE BLED AIR FROM SYSTEM AND BELLY DRAINS. AIRCRAFT RUNUP AND SYSTEM FUNCTIONED NORMALLY. AIRCRAFT RETURNED TO SERVICE.

CA040604013

SWRNGN

GARRTT

 

PLANETARY GEAR

FLAKING

5/29/2004

SA227AC

TPE33111U

 

31025613

GEARBOX

(CAN) INSTALLED PLANETARY GEAR BRG INTO ENG, DURING ROUTINE ENG CAM INSP. 16.4 HOURS LATER, ACCOMPLISHED FIRST SOAP SAMPLE IAW MFG EMM. MAJOR SILVER PARTICLES WERE FOUND IN OIL, MFG RECOMMENDED RESAMPLE. BOTH AGAIN HAD SILVER PARTICLES IN OIL. MFG RECOMMENDED TO INSPECT THIS ENG IMMEDIATELY, ENG WAS REMOVED AND REPLACED, ENG TEARDOWN INSP IN ORDER TO DETERMINE CAUSE FOR METAL IN OIL, DUE TO MAJOR SILVER. ENG HAD 101.7 HRS SINCE CAM AND 129 CYC WHEN IT WAS REMOVED. DURING INSP IT WAS FOUND THAT TWO PLANETARY GEARS O/H HAD LARGE AMOUNTS OF SILVER MISSING, FLAKING OFF BRG CAGE SURFACES. OTHER TWO PLANETARY GEAR BRGS INSTALLED HAD MINOR AMOUNT OF SILVER WORN OFF WHICH WAS SMALL IN COMPARISON ABOVE MENTIONED BRGS.

CA040322003

SWRNGN

GARRTT

 

ENGINE

FLUCTUATES

3/12/2004

SA227AC

TPE33111U

 

 

LEFT 

(CAN) AIRCRAFT TOOK OFF AND THEN PILOT RETURNED WHEN HE NOTICED THAT THE LT ENGINE EGT WAS FLUCTUATING. RUNUPS WERE CARRIED OUT BY MAINTENANCE AND CONFIRMED THAT WHEN THE SHORT HARNESS WIRING WAS WIGGLED THE INDICATION WOULD FLUCTUATE. CONTACTS WERE CLEANED AND WIRING SECURED. NO OTHER FLUCTUATIONS HAVE BEEN NOTICED SINCE .

CA040624004

UROCOP

TMECA

 

HOLDER

LOOSE

6/14/2004

EC155B

ARRIEL2B

 

DHS78212010

FUSE 

(CAN) AC HAS THREADED TYPE FUSE HOLDERS. IN CRUISE, LOST OIL PRESSURE INDICATION ON NR 2 ENGINE. LOW PRESSURE LIGHT DID NOT COME ON, (IT'S ON A SEPARATE PRESS SWITCH). PILOT REDUCED NR 2 ENG TO IDLE. TEMP REMAINED NORMAL WITH NO OTHER CHANGES IN SYSTEMS. AN UNEVENTFUL LANDING WAS COMPLETED. INVESTIGATION REVEALED FUSE HOLDER HAD VIBRATED LOOSE AND CAUSED FUSE FOR OIL PRESSURE INDICATION TO LOSE CONTACT CAUSING A POWER LOSS FOR THE INDICATOR. ABOUT 10 OTHER FUSE HOLDER CAPS WERE ALSO FOUND LOOSE. FUSE HOLDER HAS NO POSITIVE LOCKING FEATURE AND AS A RESULT, NOW WILL BE CHECKING PERIODICALLY. THOUGH NOT A TERRIBLY SERIOUS ISSUE IT IS ONE THAT DESERVED MENTION AS OTHER MFG PRODUCTS MAY USE SAME FUSE HOLDER.

AUS20040318

WSK  

GARRTT

HARTZL

BOLT

CRACKED

4/29/2004

M18DROMADER

TPE33111U

 

A203612

PROPELLER BLADE

(AUS) PROPELLER COUNTERWEIGHT TO BLADE CLAMP ATTACHMENT BOLTS (2OFF10) CRACKED.

 

END OF REPORTS