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

350

bald eagle watching over three eggs

SEPTEMBER

2007

 


CONTENTS

AIRPLANES

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

CESSNA...................................................................................................................................... 3

MAULE........................................................................................................................................ 7

HELICOPTERS

EUROCOPTER............................................................................................................................ 7

SIKORSKY................................................................................................................................. 7

ACCESSORIES

AEROTECH ALTERNATOR...................................................................................................... 9

ECI CYLINDER........................................................................................................................ 10

WIPAIRE................................................................................................................................... 10

AIR NOTES

INTERNET SERVICE DIFFICULTY REPORTING (iSDR) WEB SITE................................... 10

IF YOU WANT TO CONTACT US......................................................................................... 11

AVIATION SERVICE DIFFICULTY REPORTS...................................................................... 12

 


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

AVIATION MAINTENANCE ALERTS

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

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

 

AIRPLANES

BEECH

Beech: A36; Fretting Engine Mount Bolts; ATA 7120

A mechanic with an inspection authorization writes, “I performed an annual inspection on (this aircraft’s) engine and found black fretting corrosion below the center two, L/H aft engine mount bolts. (These) bolts were loose in the mount (even though...) the nuts were tight on the bolts. The problem is the bolts are a little too long—the nuts were running out of threads on the bolts. The solution was to add another washer below the nuts, then re-torque back to specifications.” (The submitter did not indicate whether or not he knew these bolts to be original—their part numbers were not provided.)


Close view of the two bolts in the engine mount structure.

Part Total Time: (1,672.1 hours.)

 

Beech: B24R; Blown Electrical Capacitor; ATA 2340

(An aircraft operator...) had drawn the battery charge down considerably, trying to start the aircraft,” states a technician. The pilot reported hearing a “pop”—then (seeing) smoke in the cabin. Take-off was aborted and an emergency gear up landing was made, resulting in substantial damage to the aircraft. On inspection a capacitor was found secured to the aft end of the audio control panel...installed in the KN4CB wire. The capacitor had the end blown out and its contents splattered on the windshield air duct.


“Probable cause: the low battery charge coupled with the high in-rush current demand of the gear motor—over and above the normal demands of the avionics—most likely resulted in an over-voltage condition, causing the capacitor to explode.”

(A similar event happened to a cohort flying an experimental several years back. He described smoke so thick in the cockpit both he and his wife were certain the aircraft was on fire. They effected a safe landing in a farmer’s field, later discovering a three dollar part the cause of their near calamity—Ed.)

Part Total Time: (unknown).

 

CESSNA

Cessna: 172K; Chafing Fuel Line; ATA 2820

A mechanic writes, “During an Annual Inspection, both engine fuel supply lines were found to be chafing on the forward bulkhead of the landing gear box structure at (bulkhead) station 56.70. Cessna has installed a thin plastic sleeve over the lines in the area of the chafe, but after 2,564 hours this sleeve is chafed to the extent the tubes will no longer be protected. I feel the tube integrity would be compromised in the future. Additional chafe protection and line security (hardware) is required. The Cessna 172 IPC (internal parts catalog; figure 167) illustration shows a heavier chafe barrier installed on the tubes in the area noted above. I suggest bonding a length of MIL-H-6000 3/8 inch (inside dimension) over the Cessna line in the chafe areas. Additional adjustment of the existing line clamps may also be required. See the attached illustrations.”


Parts catalog drawing of the line location in the airplane.


Parts catalog drawing of the specific bulkhead.

 


 

Parts catalog drawing of the line passage in detail.

(Good eyeballs, Mike...and good advice!—Ed.)

Part Total Time: 2,564.6 hours.

 

Cessna: T310Q; Leaking Pitot System; ATA 3411

A mechanic states, “During a routine pitot/static test it was found the pitot system was leaking beyond limits. The leakage was determined to be in the tubing—from the pitot tube to the forward cabin bulkhead fitting.

“Upon removing the tube (P/N 0800106-379) severe corrosion was found (on this line) at the aft end, near the fitting. This portion (of the static line) was found half buried in the outer insulation of a heat duct on the left, outboard side—allowing moisture to be trapped. This area is difficult to inspect and damage to the tube could go undiscovered until a leak test is performed.

“It is recommended operators of 310 series aircraft have this line inspected, and that chafe protection be applied to the tube where it contacts the insulation of the heat duct.”

Part Total Time: (unknown).

 


MAULE

Maule: M7-235-C; Improper Seal of Main Gear Drag Link; ATA 3213

A repair station submitter writes, “This aircraft came in for its first annual inspection after installation...(of Wipline 3000A floats). Upon inspection (we) found the main gear drag link (P/N 30A04000-091) had not been properly sealed at the lower end, allowing water to enter the assembly. Because of the sealant we are unable to tell if the inside of the tube has some sort of corrosion protection. (One may wish...) to consider doing away with the sealant and applying a corrosion preventative compound, coupled with recurrent inspections and reapplication of CPC (corrosion preventative compounds).”

Part Total Time: 86.8 hours.

 

HELICOPTERS

EUROCOPTER

Eurocopter: EC 130-B4; Engine Chip Detection; ATA 7930

The director of maintenance for an operator states, “A precautionary, off-airport landing (was made) due to an engine oil chip annunciation light in flight. (There was...) an uneventful landing: no injuries; no damage to the aircraft or property. Maintenance investigated and found one small, hair-like dark chip. The plug was cleaned and the engine was test run for ten minutes. The engine run-down time was checked—it was normal. No additional chips were found. The aircraft was flown back to the maintenance base empty (of passengers). The chip plug was re-inspected for additional chips and (another) very small chip was noted. The chip plug was pulled on the accessory case and one small chip was noted there as well. The engine oil was drained, strained, and inspected for chips—none were found. The oil filter was removed and inspected—no chips. (The engine oil and filter were replaced with new, then a ground run was performed for 10 minutes.) No chips were found on either plugs.” “The aircraft was test flown for approximately fifteen minutes. (No chips were found after the flight.) As per the manufacturer’s instructions, the chip detector(s) is to be re-inspected after the first flight of the day for the next 25 flight hours.

“Probable cause: the chip detector(s) and support systems worked properly, alerting the pilot of a potential problem. (There was...) a false indication because of the chip detector’s inability to differentiate one versus many chips.” (No part number accompanied this report.)

Part Total Time: 1,999.7 hours.

 

SIKORSKY

Sikorsky: S92A; Failed Brake Stator; ATA 3242

A submitter from the Great Lakes region says, “During a (left hand, outboard) wheel change, (we) could not remove the wheel off the axle. (We) found one of the center stators (P/N A35579) of the brake assembly to be protruding out of the pack. The stator cut into the wheel, preventing its removal. We did not tear down the brake but suspect either the stator is out of round or has internal diameter damage, or the torque tube is damaged—allowing the stator to shift beyond the pack circumference." (Sikorsky brake P/N: 78286/92250-00801-102; Messier Bugatte P/N: C20497000)


 

Picture of wheel with stator gouge marks.

 

A closeup picture of the same.


 

A top view of the worn stator.

(Thanks Kirk, for the communication and effort!)

Part Total Time: 572.0 hours.

 

ACCESSORIES

AEROTECH ALTERNATOR

Aerotech Alternator: 646843; Improper Assembly; ATA 2421

A repair station technician states, “Upon receipt of (this) current alternator we noticed the Slip-Ring Housing was clocked 180 degrees out of alignment—out of the box, from Aerotech. This plane has had several Aerotech...alternators installed on it. The most recent alternator had only 131.1 hours before it failed, and the previous one 67.2 hours (before it too failed). There have been other aircraft (on which) we have had to replace low time Aerotech overhauled alternators.

“We see what seems to be a possible problem with Quality Control or the manufacturing of these appliances.”

(A search of the FAA Service Difficulty Reporting System data base reflects eight entries for this item; P/N 646843.)

Part Total Time: 0.0 hours.

 


ECI CYLINDER

ECI Cylinder: EC636122ST; Improper Machining; ATA 8530

(The following repair station submission is a composite of three identical reports reflecting the same part numbers.)

(I) installed this cylinder assembly on a newly overhauled engine, then discovered oil leaking around the cylinder base during the test cell run. I removed the cylinder and determined the cylinder base is not properly machined. There is no radius at the area where the O-ring seal is to seat. This (condition) does not allow the O-ring to properly seal against the crankcase. I used radius gauges and other cylinders to compare and make the determination there was a problem with the cylinder (P/N EC 636122ST).”

Part Total Time: 0.0 hours.

 

WIPAIRE

Wipaire: Wipline 3000A Floats; Leaking Hydraulic Hose; ATA 2910

(The following description concerns an M7-235C Maule on floats.)

(This) aircraft came in for its first annual (inspection) after certification (i.e., a new plane). On inspection hydraulic fluid was found to be coming from the forward fuselage drain. Upon removal of the floor the insulation was found to be saturated with hydraulic fluid. The system was refilled and trouble-shot—the leak was tracked to a hose (P/N: 21A09000-204). Inspection of the hose revealed the end was not properly installed, resulting in the fluid leak.

“This (leak) was a result of improper assembly of the hose by Wipline—it should have been caught during pressure testing after initial assembly.”

Part Total Time: 86.8 hours.

 

AIR NOTES

INTERNET SERVICE DIFFICULTY REPORTING (iSDR) WEB SITE

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

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

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


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

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

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

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

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

The SDRS and iSDR web site point of contact is:

Tom Marcotte
Service Difficulty Reporting System, Program Manager
Aviation Data Systems Branch, AFS-620
P.O. Box 25082
Oklahoma City, OK 73125
Telephone: (405) 954-6500
SDRS Program Manager e-mail address: 9‑AMC‑SDR‑ProgMgr@faa.gov

 

IF YOU WANT TO CONTACT US

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

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

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

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

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

 


AVIATION SERVICE DIFFICULTY REPORTS

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

2007FA0000662

 

 

 

STARTER

BURNED

6/28/2007

 

 

 

MZ422

 

STARTER BURNED UP ON TEST CELL RUN. (K)

2007FA0000669

 

CFMINT

 

DAMPER

FAILED

7/10/2007

 

CFM563C1

 

DN3351053050

ENGINE

WAS NOTIFIED BY TEST CELL OPERATOR THAT DAMPER ASSY PN DN335-105-305-0 CAME APART DURING ENGINE TEST CELL OPERATIONS OF ENGINE DURING ENGINE TEST AND AFTER POST ENGINE ADJUSTMENT. THE DAMPER ASSY WAS DISCOVERED IN THE ENGINE INLET AREA. (K)

2007FA0000685

 

CONT

 

OIL FILTER

CONTAMINATED

7/12/2007

 

IO520M

 

ES48109

ENGINE

THE ENGINE OIL SYSTEM WAS CONTAMINATED BY OIL FILTER SEAL DEBRIS. (K) ON DISASSEMBLY OF THE ENGINE RUBBER DEBRIS WAS FOUND: IN THE OIL PASSAGE THAT FEEDS THE STARTER ADAPTER WITH THE ADAPTER PILOT BEARING PLUGGED. UPON SPLITTING OF THE ENGINE CASE DEBRIS WAS FOUND IN THE OIL PASSAGE TO THE NR 3 MAIN BEARING. BOTH OIL COOLING JETS TO NR 3 MAIN BEARING WERE PLUGGED WITH RUBBER DEBRIS. THE RIGHT WAS PLUGGED WITH A PIECE .6250 INCH LONG AND THE LT WITH A PIECE .1875 INCH LONG. ONE PIECE OF RUBBER DEBRIS WAS LOCATED IN THE OIL PASSAGE TO THE NR 5 BEARING. (K)

CA070629001

 

GARRTT

 

SHAFT

WORN

6/25/2007

 

TPE33110

 

8941241

SPLINES

(CAN) AIRCRAFT EXPERIENCED A NTS EVENT DURING LANDING PHASE, WITH POWER LEVER REDUCED TO FLIGHT IDLE, AC CONFIGURED FOR LANDING, WITH NORMAL ATTITUDE FOR LANDING. AIRCRAFT LANDED AND TAXIED WITH NO OTHER PROBLEMS REPORTED. AIRCRAFT INSPECTED, FLIGHT IDLE BLADE ANGLES ADJUSTED AND RETURNED TO SERVICE. DUE TO SOAP RESULTS AND NTS GROUND CHECK RESULTS, THE ENGINE WAS SUBSEQUENTLY REMOVED FROM SERVICE. NTS ACTION IS POTENTIALLY DUE TO (SUSPECTED) COMBINATION OF WEAR OF THE QUILL SHAFT AND BALL LOCK WHICH WOULD HAVE IN EFFECT, CAUSED A REDUCTION IN THE PRELOAD OF THE NTS SYSTEM, THEREBY ALLOWING THE NTS TO ACTIVATE AT A LOWER THRESHOLD THAN SET CALIBRATION. CODE (TC NR20070629001)

CA070704001

 

GARRTT

 

EXHAUST DUCT

CRACKED

7/3/2007

 

TPE33110UA

 

31015827

ENGINE

(CAN) UPON ROUTINE INSPECTION, THE MAINTENENCE CREW FOUND THE EXHAUST DUCT CRACKED. THE ENGINE WAS REMOVED AND THE EXHAUST DUCT WAS REPLACED WITH A OVERHAULED ONE. NO OTHER PROBLEMS WERE DETECTED AT THIS INSPECTION. (TC NR 20070704001)

CA070726004

 

GE  

 

SEAL

CRACKED

7/26/2007

 

CT581402

 

4017T37P02

COMPRESSOR

(CAN) MULTIPLE CRACKS THROUGH KNIFE EDGE SEALS. THIS REPORT WILL ALSO BE SUBMITTED TO MFG IAW SEI-183 SECTION 72-32-7 PAGE 302. (TC NR 20070726004)

CA070725006

 

LYC  

 

CRANKCASE

DAMAGED

7/25/2007

 

O360A3A

 

0360A3A

ENGINE

(CAN) OVERHAULED CYLINDER ASSY`S WERE INSTALLED APPROX 500 HRS AGO ONTO A FRETTED CRANKCASE. THE CENTER MAIN BEARING THEN SPUN IN THE BEARING SADDLE. METAL WAS DETECTED IN THE OIL SCREEN AND THE ENGINE WAS SUBSEQUENTLY TORN DOWN FOR OVERHAUL. THE CRANKCASE IS UNSERVICEABLE. (TC NR 20070725006)

CA070704015

 

PWA  

 

ENGINE

SEIZED

5/11/2007

 

PT6A65AR

 

 

 

(CAN) IN CRUISE, SMOKE WAS OBSERVED IN THE CABIN AND ENGINE POWER REDUCED UNCOMMANDED. THE ENGINE WAS SHUTDOWN IN FLIGHT AND THE AIRCRAFT DIVERTED TO POINT OF DEPARTURE. SUBSEQUENT INSPECTION REVEALED SEIZURE OF THE ENGINE AND OIL LEAKAGE. MFG WILL MONITOR THE INVESTIGATION OF THE EVENT AND WILL ADVISE OF ROOT CAUSE ONCE ESTABLISHED. (TC NR 20070704015)

2007FA0000681

 

PWA  

 

SEAL

LEAKING

7/31/2007

 

R1340AN1

 

13814

SUPERCHARGER

DISASSEMBLY OF THE ENGINE AND OR REAR SECTION AFTER CUSTOMERS REPORTED SMOKING AND INCREASE IN OIL CONSUMPTION. DURING THE DISASSEMBLY IT WAS FOUND THAT BLOWER SEALS HAVE FAILED AND BEEN LEAKING.

CA070705003

AEROSP

PWA  

 

SEAL

LEAKING

5/28/2007

ATR42320

PW121

 

3022383

STARTER GEN

(CAN) ON A MAINTENANCE FLIGHT, THE ENGINE LOW OIL PRESSURE WARNING ACTIVATED AND THE ENGINE WAS SHUTDOWN IN FLIGHT. SUBSEQUENT INSPECTION REVEALED A LEAKING STARTER GENERATOR GARLOCK LIP SEAL. (TC NR 20070705003)

CA070704009

AEROSP

PWA  

 

PACKING

DEFECTIVE

5/9/2007

ATR72

PW127

 

ST3367009

FUEL MANIFOLD

(CAN) SHORTLY AFTER TAKE-OFF PASSENGERS REPORTED FLUID ESCAPING FROM THE ENGINE. THE PILOT REDUCED ENGINE POWER AND DIVERTED TO POINT OF DEPARTURE. SUBSEQUENT INSPECTION REVEALED LEAKING FUEL NOZZLE MANIFOLD PACKINGS. MFG HAS DETERMINED THE PACKINGS TO BE ASSOCIATED WITH A MANUFACTURER`S QUALITY ESCAPE (REFERENCE: MFG SERVICE BULETIN SB21740) (TC NR 20070704009)

CA070803003

AEROSP

PWA  

 

AUTOFEATHER SYS

DEFECTIVE

6/1/2007

ATR72

PW127

 

3004800001

PROP CONTROL

(CAN) THE ENGINE WAS REPORTED TO HAVE EXPERIENCED AN INFLIGHT SHUTDOWN. AUTOFEATHER CONTROL UNIT WAS SUBSEQUENTLY REPLACED. (TC NR 20070803003)

CA070704014

AEROSP

PWA  

 

PACKING

FRACTURED

5/19/2007

ATR72212

PW127

 

ST3367009

FUEL MANIFOLD

(CAN) FUEL WAS FOUND LEAKING FROM THE FUEL MANIFOLD DRAIN DURING TAXI. SUBSEQUENT INSPECTION REVEALED LEAKING FUEL MANIFOLD PACKINGS. MFG HAS DETERMINED THE PACKINGS TO BE ASSOCIATED WITH A MANUFACTURER`S QUALITY ISSUE (REFERENCE MFG SB21740). (TC NR 20070704014)

CA070731001

AIRBUS

GE  

 

SEAL

LEAKING

7/27/2007

A310300

CF680C2A5

 

 

HMU 

(CAN) DURING TAXI-IN AT THE GATE, A LARGE FUEL LEAKAGE WAS OBSERVED COMING FROM THE HMU FUEL DRAIN BELOW NR 2 ENGINE. ENGINE WAS SHUTDOWN, BUT LEAKAGE CONTINUED. NR 2 ENGINE FIRE HANDLE WAS PULLED AND LEAKAGE STOPPED. FOUND LEAKAGE WAS FOM THE MEC SHAFT SEAL. MEC WAS REPLACED AND AIRCRAFT RETURNED TO SERVICE. (TC NR 20070731001)

CA070716002

AIRBUS

CFMINT

 

WARNING MESSAGE

ACTIVATED

7/13/2007

A320211

CFM565A1

 

 

STAB TRIM

(CAN) AFTER DEPARTURE, AN ECAM MSG INDICATED STAB TRIM FAILURE. NEITHER OF THE AUTOPILOTS COULD BE RE-ENGAGED. AN EMERGENCY WAS DECLARED WITH ATC AND THE FLIGHT LANDED APPROX 7.5 TONS OVERWEIGHT. (TC NR 20070716002)

2007FA0000727

AIRTRC

PWA  

HAMSTD

BLADE

BROKEN

6/20/2007

AT301

R1340AN1

 

6533A12

PROPELLER

(9 INCHES) OF PROP BLADE BROKE OFF IN FLIGHT. THE SEVERE VIBRATION CAUSED PILOT TO LAND IN MUDDY FIELD. AIRCRAFT WAS TOTALED. (K)

CA070803005

AIRTRC

PWA  

 

TURBINE BLADES

FRACTURED

5/30/2007

AT802A

PT6A67A

 

 

ENGINE

(CAN) THE ENGINE LOST POWER ON TAKEOFF ROLL AND THE TAKEOFF WAS ABORTED. SUBSEQUENT INSPECTION REVEALED FRACTUED POWER TURBINE BLADES AND A DISCONNECTION BETWEEN THE POWER TURBINE AND PROP. MFG WILL INVESTIGATE THE EVENT AND ADVISE OF ROOT CAUSE ONCE ESTABLISHED. (TC NR 20070803005)

CA070618003

AIRTRC

PWA  

 

ACTUATOR

FAILED

6/16/2007

AT802A

PT6A67A

 

20619502

TE FLAP

(CAN) DURING APPROACH FOR A SCOOPING OPERATION, THE FLAPS WOULD NOT EXTEND WITH AN AIR LOAD. THE AIRCRAFT RETURNED TO BASE. UPON INVESTIGATION BY MAINTENANCE STAFF, FLAPS WOULD EXTEND THE FIRST 10 DEGREES WITH NO AIR LOAD AND THE ACTUATOR MADE A GRINDING NOISE. THE FLAP ACTUATOR WAS REPLACED AND THE AIRCRAFT WAS RETURNED TO SERVICE. (TC 20070618003)

CA070509003

AMD  

GARRTT

 

SIGNAL COND UNIT

MALFUNCTIONED

5/4/2007

FALCON10

TFE73121C

 

360930001

FUEL INDICATOR

(CAN) IN FLIGHT, ON THE WAY BACK TO BASE THE CREW NOTICED THE RT FUEL GAUGE WAS INTERMITTENT AND NOT WORKING MOST OF THE TIME. THE DEFECTIVE PART WAS JUST REPLACED 7 HOURS PRIOR WITH THE SAME ISSUE. ANOTHER SIGNAL CONDITIONER HAS BEEN INSTALLED AND CALIBRATED. THERE HAS BEEN NO FAULTS SINCE THE REPLACEMENT. (TC NR 20070509003)

CA070123012

AMD  

 

 

CONTROL UNIT

FAILED

1/19/2007

FALCON2000

 

 

RVA7101

OXYGEN SYSTEM

(CAN) UPON A NON-ROUTINE DEPLOYMENT OF THE OXYGEN MASKS ON THE GROUND BY MAINTENANCE. OXYGEN CONTROL UNIT (10WJ) WAS PLACED INTO (OVERRIDE) TO MANUALLY DEPLOY THE PAX OXYGEN MASKS. THEY DID NOT DEPLOY ON COMMAND. MULTIPLE ATTEMPTS WERE MADE TO MANUALLY DEPLOY THE PAX OXYGEN MASKS IN (OVERRIDE). THEY STILL DID NOT DEPLOY. OXYGEN CONTROL UNIT (10WJ) WAS REPLACED IAW MP35-203, OPS TESTED SERVICEABLE. PN OFF: RVA71-01 SN OFF: 0640 ATSO: 1563.8 ACSO: 711. FAULTY OXYGEN CONTROL UNIT FORWARDED TO MFG FOR EXCHANGE. (TC NR 20070123012)

CA070725002

AMD  

CFE  

 

DRAIN VALVE

DAMAGED

3/22/2007

FALCON2000

CFE73811B

 

6BS10011

 

(CAN) THE AIRCRAFT POTABLE WATER SYSTEM WAS DAMAGED DUE TO HAVING THE WATER SYSTEM FULL OF WATER. THEN PARKING THE AIRCRAFT ON THE RAMP FOR 8 HRS AT -14 DEGREES C. WITH NO ADDITIONAL HEAT TO KEEP THE WATER SYSTEM FROM FREEZING. UPON ARRIVING, THE PILOTS REPORTED (WATER APPEARS TO LEAKING FROM THE BELLY) THE MAINTENANCE PERSONAL INVESTIGATED THE PROBLEM AND FOUND THE WATER SYSTEM DRAIN VALVE WAS DAMAGED DUE TO THE SEVERE FREEZING OF THE WATER SYSTEM. THE DRAIN VALVE WAS REPLACED AND THE AIRCRAFT RETURNED TO SERVICE. A REMINDER TO ALL PILOTS TO MONITOR THE POTABLE WATER SYSTEM AND THE OAT IN THE WINTER. (TC NR 20070725002)

2007FA0000710

AMTR

LYC  

 

FLOAT

SATURATED

6/3/2007

COZY

O290*

 

30804

CARBURETOR

ENGINE FAILED ON SHORT FINAL DUE TO CARB FLOODING FLOAT IN CARB HALF FULL OF GAS.

CA070720010

BAG  

 

 

A/C PACK

SEIZED

7/18/2007

JETSTM3212

 

 

15310000

RIGHT

(CAN) PILOT REPORTED OVER TEMP LIGHT, AND CONTINUED FLIGHT IAW J-31 MEL. UPON TROUBLESHOOTING IT WAS FOUND THAT THE RT CAU WAS SEIZED. CAU WAS REPLACED WITH OVERHAULED UNIT AND AIRCRAFT RETURNED TO SERVICE. THIS UNIT HAS A 6000 HOUR LIFE BETWEEN OVERHAULS, AND FAILED AFTER 327.5 HOURS IN SERVICE. SEIZED UNIT WILL BE SENT FOR WARANTY OVERHAUL. (TC# 20070720010)

2007FA0000714

BBAVIA

CONT

 

SPAR

CRACKED

7/26/2007

7FC  

C90*

 

5146R

WING 

AIRCRAFT WAS BEING MODIFIED TO INCLUDE THE INSTALLATION OF WING SPAR INSP HOLE KITS AS SUPPLIED IAW STC NR SA00527SE. A PORTION OF THE WING LEADING EDGE SKIN WAS REMOVED AND THE WING SPAR WAS VISUALLY INSPECTED AS SPECIFIED IN THE INSTALLATION INSTRUCTIONS SUPPLIED WITH THE STC. DURING THIS VISUAL INSPECTION, A CRACK WAS OBSERVED ON THE TOP SURFACE OF THE RT WING FRONT SPAR. THE CRACK WAS OBSERVED ON THE TOP SURFACE OF THE RT WING FRONT SPAR. THE CRACK ORIGINATES AT THE IB END OF THE AFT PLYWOOD REINFORCEMENT PLATE. REINFORCEMENT PLATE IS LOCATED ON THE AFT SIDE OF THE FRONT SPAR, UNDER THE LIFT STRUT ATTACHMENT FITTING. THE CRACK PROGRESSES OB ALONG THE TOP SURFACE OF THE SPAR AT A SLIGHT FWD ANGLE (CRACK ANGLES TOWARD THE FORWARD PLYWOOD REINFORCEMENT PLATE). THE SURFACE OF THE CRACK IS ALONG THE TOP OF THE SPAR, NOT THROUGH BOLT HOLES OR NAIL HOLES. THE AIRCRAFT MAINTENANCE RECORDS INDICATE THAT A WING SPAR INSPECTION HAD PREVIOUSLY BEEN COMPLETED IAW AD 2000-25-02. THE AC SHOWED NO EVIDENCE OF ACCIDENT/INCIDENT WING DAMAGE SUBSEQUENT TO SAID INSPECTION. THIS COPY OF THIS FORM HAS BEEN MAILED TO THE SPECIFIED IN AD. (K)

2007FA0000631

BBAVIA

LYC  

 

SPAR

CRACKED

6/28/2007

7GCAA

O320A2B

 

5262 

RT WING

(2) LONGITUDINAL CRACKS AT SPAR HINGE FITTING. SHAKING AND EXPANDING OF WOOD FIBERS DUE TO MOISTURE OR LACK OF. RECOMMEND USING ALUMINUM SPARS OF SUFFICIENT SIZE AND STRENGTH. (K)

2007FA0000702

BBAVIA

LYC  

 

BEARING

CRACKED

8/3/2007

7GCB

O320*

 

S18233

STEERING ROD

NOSE LANDING GEAR STEERING ROD END BEARING (P/N S-1823-3) FAILED IN THREADED PART OF ROD, ALLOWING NOSE GEAR TO TURN SIDEWAYS, RESULTING IN EXCESSIVE SIDE LOAD ON NOSE LANDING GEAR ASSEMBLY, CAUSING IT TO FAIL AND SEPARATE FROM THE AIRCRAFT RESULTING IN MINOR DAMAGE TO COWLING, PROPELLER, EXHAUST PIPES. THIS ROD END BEARING SHOWS SIGNS OF CORROSION, PITTING AND IS PROBABLY THE ORIGINAL 1963 PART.

CA070705005

BEECH

PWA  

 

FCU  

DEFECTIVE

3/3/2007

1900C

PT642A

 

3244768

ENGINE

(CAN) IN FLIGHT THE ENGINE EXPERIENCED AN UNCOMMANDED ACCELERATION RESULTING IN AN OVER-TORQUE CONDITION. SUBSEQUENT INSPECTION REVEALED A FAULTY FCU. (TC NR 20070705005)

CA070619002

BEECH

PWA  

 

STEP

CRACKED

6/18/2007

200BEECH

PT642A

 

504300401

PAX DOOR

(CAN) DURING AN INSP IT WAS NOTICED THAT THE STEP ON THE AIRSTAIR DOOR WAS CRACKED AT THE PIVOT STUD. THE STEP WAS REMOVED AND A SERVICEABLE STEP WAS INSTALLED. (TC NR 20070619002)

CA070618005

BEECH

PWA  

 

POWER LEVER

WORN

5/4/2007

200BEECH

PT6A41

 

509440767

LT ENGINE

(CAN) FLIGHT SNAG REPORTED - (LT ENGINE REMAINS AT HIGH IDLE AT LOW IDLE SETTINGS). MAINTENANCE FOUND THE AIRFRAME POWER LEVER ARM AT THE REVERSING CAM GROUND PIN HEAD JUMPED THE SPLINE, CAUSING THE SHOULDERED PIN TO HOLD THE FCU INTERCONNECT ARM FROM RESETTING TO GROUND IDLE.THE ARM WAS RE-ADJUSTED AND IS ASSUMED WORN OUT INTERNALLY. AS A PRECAUTION ALL THROTTLE ARMS WERE REPLACED. (TC NR 20070618005)

2007AP081001

BEECH

PWA  

BEECH

TORQUE TUBE

WORN

8/10/2007

200BEECH

PT6A41

 

1016100190014

ELEVATOR

WHILE UNDERGOING A SCHEDULED INSPECTION, FOUND THE RT ELEVATOR HAD DEVELOPED VERTICAL PLAY WHEN GRASPED FROM THE TRAILING EDGE. FOUND THE ELEVATOR TORQUE TUBE HAD ROTATIONAL WHERE THE 6 EACH OB BLIND RIVETS ATTACH THE TORQUE TUBE TO THE MOUNT PLATE.

2007FA0000712

BEECH

 

 

SQUIB

GROUNDED

7/27/2007

300BEECH

 

 

 

FIRE BOTTLE

DURING COMPLETION OF THE INITIAL 200 HOUR PHASE 1 INSPECTION, THE RT ENGINE FIRE BOTTLE SQUIB WAS FOUND TO BE IN A GROUNDED CONDITION. THE TERMINALS WERE WIRED TOGETHER WITH SAFETY WIRE AND A TAG THAT STATED (DISCONNECT AT INSTALLATION, THE AIRCRAFT SQUIB WIRING WAS ATTACHED OVER THE SAFETY GROUND WIRE. THIS GROUNDED CONDITION IS TYPICALLY FOUND ON SQUIBS THAT ARE PACKAGED FROM THE VENDOR FOR SHIPPING. DURING INSTALLATION OF THE SQUIB ONTO THE FIRE BOTTLE, THE SAFETY GROUND IS REMOVED. IN THIS CONDITION, THE SQUIB CANNOT DETONATE TO PUT OUT AN ENGINE FIRE. LOG BOOKS WERE NOT AVAILABLE FOR RESEARCH AT THE TIME THE DISCREPANCY WAS DISCOVERED, ALTHOUGH THE AIRCRAFT WAS NEW ENOUGH THAT IT WAS UNLIKELY ANY ENGINE FIRE EXTINGUISHER SYS MAINTENANCE HAD BEEN PREVIOUSLY ACCOMPLISHED. INSTALLATION WAS SUBSEQUENTLY CORRECTED AND MFG SUPPORT WAS NOTIFIED TO ASSIST IN CORRECTIVE ACTIONS. (K)

2007FA0000686

BEECH

PWA  

 

RIB  

CRACKED

7/13/2007

400A

JT15D5

 

45A2110422

HORIZONTAL STAB

HORIZONTAL STABILIZER LEADING EDGE IB RIBS ARE CRACKED AT THE ROLLER BRACKET ATTACHMENT POINTS. SAFETY COMMUNIQUE NR 70 IS ONLY PUBLISHED CRITERIA CONCERNING THIS PROBLEM. (K)

2007FA0000659

BEECH

CONT

 

ROD END

UNSERVICEABLE

7/12/2007

58  

IO520*

 

HMXL6G

NLG 

DURING EXAMINATION OF AIRCRAFT POST INCIDENT, IT WAS DISCOVERED THAT ROD END (PN HMXL6G) ATTACHED TO THE NOSE GEAR RETRACT ARM (PN 35825172-2) WAS SHEARED OFF BELOW THE BEARING. IT APPEARS THE FAILURE STARTED IN A CRACK IN THE THREADS. THIS MOST LIKELY RELEASED THE OVER CENTER TENSION ON THE NOSE GEAR DOWNLOCK ALLOWING THE NOSE GEAR TO RETRACT AND SUBSEQUENTLY THE MAIN LANDING GEAR. RECOMMEND ANNUAL PENETRANT INSPECTION OF ALL LANDING GEAR RETRACTION ROD ENDS. (K)

2007FA0000715

BEECH

LYC  

 

ACCUMULATOR

RUPTURED

8/7/2007

76  

LO360A1G6

 

8907021

HYS SYS

DURING TRAINING FLIGHT IN PREP FOR COMMERCIAL/AMEL, PILOT PERFORMED INTENTIONAL SHUTDOWN OF LT ENGINE (FEATHERED). WAS UNABLE TO RESTART WITH ACCUMULATOR AND BEGAN PROCEDURE TO RESTART WITHOUT ACCUMULATOR WHICH WAS UNSUCCESSFUL. PILOT RETURNED TO DEPARTURE AND LANDED. AN INVESTIGATION OF THE ACCUMULATOR REVEALED A RUPTURED DIAPHRAGM. REPLACED LT ACCUMULATOR AND RT ACCUMULATOR WAS REPLACED AS A PRECAUTIONARY METHOD. (K)

CA070621002

BEECH

LYC  

 

MOTOR

CONTAMINATED

6/16/2007

76  

O360A1G6D

 

 

HYD SYSTEM

(CAN) DURING APPROACH, PILOTS SELECTED LANDING GEAR DOWN, GEAR MOTOR CIRCUIT BREAKER POPPED AND GEAR WOULD NOT EXTEND. AN EMERGENCY EXTENSION WAS CARRIED OUT SATISFACTORILY. AFTER RETURN TO BASE MECHANICS FOUND THAT THE HYDRAULIC MOTOR WAS CONTAMINATED WITH HYDRAULIC FLUID WHICH LED TO AN ELECTRICAL SHORT. FURTHER INSPECTION FOUND THAT THE O-RING WHICH SEPARATES THE RESERVOIR AND THE MOTOR WAS DETERIORATED. MECHANICS FOUND THAT SPARE POWER PACKS IN STORES HAD SIMILAR CONTAMINATION DUE TO FAULTY O-RINGS. THESE SPARE POWER PACKS ARE LAID ON THEIR SIDES WHICH WOULD ALLOW FLUID TO PASS TO THE MOTOR. A FLEET WIDE INSPECTION OF POWER PACKS IN SERVICE IS BEING CARRIED OUT BY THE AMO TO PREVENT FURTHER OCCURRENCES. A MEMO HAS BEEN ISSUED TO STORES PERSONNEL ABOUT STORAGE OF POWERPACKS. (TC NR 20070621002)

CA070621003

BEECH

LYC  

 

FRAME

SEPARATED

6/20/2007

76  

O360A1G6D

 

1058100237

RT WING

(CAN) DURING TAXI PILOTS FELT THE RT WING DROP SUDDENLY AND HEARD A TIRE SKIDDING SOUND. THEY IMMEDIATELY STOPPED THE AIRCRAFT. MECHANICS FOUND THE LANDING GEAR A-FRAME HAD BROKEN FREE FROM THE MAIN LANDING GEAR TRUNNION. THE LANDING GEAR DID NOT COLLAPSE BUT ROTATED OB AND CONTACTED THE WING WHEEL WELL SKIN CUTOUT, AFTER THE A-FRAME BECAME DISCONNECTED. THE A-FRAME THAT FAILED HAD BEEN REPLACED WITH AN IMPROVED DESIGN AS REQUIRED BY AD 97-06-10. A FLEET WIDE INSPECTION OF A-FRAMES IN SERVICE ON COMPANY OPERATED AIRCRAFT IS BEING CONDUCTED BY THE AMO TO DETECT EVIDENCE OF CRACKS AT THE WELD BETWEEN THE UPPER ATTACH FITTING (SQUARE SHAPE) AND THE ROUND TUBULAR STRUCTURE. (TC NR 20070621003)

2007AP0821001

BEECH

 

 

TERMINAL

BROKEN

8/9/2007

B200

 

 

36153

RT GCU

WIRE NUMBER P73G16N AT RT ENGINE FIREWALL GROUND POINT GS15 SEPARATED FROM THE WIRE TERMINAL DURING CRUISE FLIGHT. THIS WIRE CONNECTS GROUND TO THE GCU PIN G. THE RT GENERATOR OUTPUT SPIKED AND OPENED THE 325 AMP RT BUSS CURRENT LIMITER, THE 50 AMP RT INVERTER CURRENT LIMITER, AND DAMAGED RADIOS, THE GCU AND SYSTEMS WIRED TO THE RT BUSS. UPON INSPECTION, THE INSULATION OF P73G16N WAS FOUND STRIPPED TOO FAR FROM THE WIRE END THEREBY GIVING NO SUPPORT OF THE WIRE INTO THE TERMINAL AT THE INSULATION CRIMP AREA.

CA070705002

BEECH

PWA  

 

SEAL

LEAKING

5/30/2007

B200

PT642A

 

 

STARTER GEN

(CAN) ENGINE OIL PRESSURE WAS SEEN TO REDUCE AND FLUCTUATE IN CRUISE AND THE ENGINE WAS SHUTDOWN IN FLIGHT. SUBSEQUENT INSPECTION REVEALED A FAULTY LIP SEAL (RECENTLY REPLACED) ON THE STARTER GENERATOR DRIVE SHAFT. (TC NR 20070705002)

CA070704017

BEECH

PWA  

 

ENGINE

OVERTEMP

5/23/2007

B200

PT642A

 

 

 

(CAN) IN CRUISE, THE ENGINE INTER-TURBINE TEMPERATURE WAS SEEN TO INCREASE AND FLAMES AND SPARKS WERE SEEN EXITING THE EXHAUST. THE ENGINE WAS SHUTDOWN IN FLIGHT. MFG WILL INVESTIGATE THE EVENT AND WILL ADVISE OF ROOT CAUSE ONCE ESTABLISHED. (TC NR 20070704017)

CA070622008

BEECH

PWA  

 

TORQUE TUBE

MISMANUFACTURED

6/12/2007

B200

PT6A42

 

1016100190014

ELEVATOR CONTROL

(CAN) DURING RIGGING CHECK, DUE TO REPLACEMENT OF THE ELEVATOR TORQUE TUBE, DISCOVERED THE ARM LOCATION WAS INCORRECT IN RELATION TO THE MOUNTING PLATE. THIS RESULTED IN NOT BEING ABLE TO ACHIEVE FULL TRAVEL OF THE ELEVATOR. THIS WAS CONFIRMED WHEN COMPARED TO THE REMOVED TORQUE TUBE AND THE SECOND REPLACEMENT. THE CONCLUSION IS INCORRECT ASSEMBLY AT MFG. (TC NR 20070622008)

2007FA0000758

BEECH

PWA  

SUNDSTRANDEM

DRIVE SHAFT

SHEARED

8/28/2007

B200

PT6A42

 

 

FUEL PUMP

WHILE AT CRUISE FLIGHT, LT ENGINE SHUTDOWN WITHOUT WARNING. LANDED WITHOUT INCIDENT. FOUND HIGH PRESSURE FUEL PUMP SHAFT SPLINES SHEARED ON INSIDE OF DRIVE COUPLING RENDERING FUEL PUMP AND FUEL CONTROL INOPERABLE. INSPECTION WOULD NOT BE POSSIBLE WITHOUT PUMP REMOVAL AND DISASSEMBLY OF DRIVE COUPLING.

2007FA0000735

BEECH

PWA  

 

GROUND WIRE

BROKEN

8/9/2007

B200

PT6A6

 

36153

GCU 

WIRE NR P73G16N AT RT ENGINE FIREWALL GROUND POINT GS15 SEPARATED FROM THE WIRE TERMINAL DURING CRUISE FLIGHT. THIS WIRE CONNECTS GROUND TO THE GCU PIN G. THE RT GENERATOR OUTPUT SPIKED AND OPENED THE 325 AMP RT BUSS CURRENT LIMITER, THE 50 AMP RT INVERTER CURRENT LIMITER, AND DAMAGED RADIOS, THE GCU AND SYSTEMS WIRED TO THE RT BUSS. UPON INSPECTION, THE INSULATION OF P73G16N WAS FOUND STRIPPED TOO FAR FROM THE WIRE END THEREBY GIVING NO SUPPORT OF THE WIRE INTO THE TERMINAL AT THE INSULATION CRIMP AREA.

CA070627001

BEECH

PWA  

 

DOWNLOCK SWITCH

UNSERVICEABLE

6/22/2007

B300

PT6A60A

 

1013646281

LT MLG

(CAN) THE AIRCRAFT WAS ON A RETURN LEG, WHEN THE CREW LOWERED THE LANDING GEAR THEY NOTICE AN UNSAFE INDICATION ON THE LT MAIN. THEY ABORTED THE LANDING AND INITIATED A (GO-AROUND) PROCEDURE. THE LANDING GEAR WAS CYCLED TWICE MORE AND ON THE SECOND TRY A SAFE INDICATION WAS OBSERVED. THE AIRCRAFT LANDED WITHOUT INCIDENT. THE LT MAIN LANDING GEAR DOWNLOCK SWITCH ASSY (P/N 101-364628-1) WAS REMOVED AND REPLACED WITH A SERVICEABLE UNIT. THE AIRCRAFT WAS RETURNED TO SERVICE. (TC NR 20070627001)

FMOR20070003

BEECH

PWA  

 

CONTROL CABLE

FRAYED

8/28/2007

C90  

PT6A60A

 

NAS302665170

FS 216

THE ELEVATOR TRIM CABLE WAS FOUND TO HAVE SEVERAL BROKEN STRANDS AND BEGINNING TO UNRAVEL WHERE IT GOES AROUND THE ELEVATOR TRIM ACTUATOR CAPSTAND. THIS CONDITION WAS MOST LIKELY CAUSED BY AGE.

CA070729002

BEECH

PWA  

 

COUNTERWEIGHT

SEPARATED

7/12/2007

D18S

R985AN14B

 

39892

ENGINE

(CAN) AIRCRAFT WAS IN CRUISE, ALL SYSTEMS NORMAL WHEN A VIOLENT VIBRATION HAPPENED IN THE LT ENGINE. ENGINE SEIZED DURING SHUTDOWN/FEATHER PROCESS AND FEATHERING WAS UNAVAILABLE. A SAFE LANDING WAS MADE ON A LAKE. INVESTIGATION REVEALED NR 1 CYLINDER COMPLETELY REMOVED FROM THE ENGINE AND NR 9 PARTIALLY REMOVED. FORWARD COUNTERWEIGHT HAD SEPARATED COMPLETELY FROM ITS ARM AND WAS FOUND LODGED IN THE TOP PART OF THE ENGINE AFTER BLOWING OUT A SECTION OF THE NOSE SIDE OF THE CRANKCASE COVER. AN ENGINE CHANGE WAS CONDUCTED ON SITE AND AIRCRAFT RETURNED TO RED LAKE WITH A LOANER PROP INSTALLED. (TC NR 20070729002)

2007FA0000698

BEECH

CONT

 

CYLINDER

CRACKED

7/30/2007

D55  

IO520CB

 

TISN712ACA

NR 6 

NR 6 CYLINDER WAS NEW ECI REV 3 E SERIES CRACKED BETWEEN FINS 1-3 BEHIND FUEL INJECTOR. THIS IS 6TH ECI REV 3 E SERIES TO CARCK IN THE SAME LOCATION. (K)

2007FA0000752

BEECH

PWA  

 

ENGINE

FAILED

7/25/2007

E90  

PT6A60A

 

 

LEFT 

AIRCRAFT IN CRUISE AT 22,000 WITH ALL ENGINE INDICATIONS NORMAL. A LOUD NOISE FOLLOWED BY POWER LOSS AND REDLINE ITT ON THE LT ENGINE. THE CT BLADES, ITT PROBES, PT VANE AND PT BLADES ALL MELTED AND WENT THROUGH THE EXHAUST STACKS. COMPRESSOR STATOR AND SPACER RUB. POSSIBLE COMPRESSOR UNSTACK FAILURE. THIS IS THE FIRST COMPLETE MELT DOWN FAILURE HAVE EVER SEEN AT ALTITUDE. (K)

2007FA0000747

BEECH

PWA  

 

TUBE

CRACKED

8/17/2007

F90  

PT6A135

 

3011849

LT ENGINE

FUEL LEAK NOTED ON SHUTDOWN OF LT ENGINE. FUEL TUBE P/N 3011849 CRACKED AT CONNECTION TO START CONTROL UNIT.

2007FA0000663

BEECH

PWA  

 

CONTROL ARM

CRACKED

11/21/2006

RC45J

R985*

 

187504

ELEVATOR

DURING COMPLIANCE WITH AD 77-19-07 PARA B, DYE PENETRANT INSPECTION REVEALED 2 POSSIBLE DEFECTS, 0.75 INCH AND 0.5 INCH LONG. BOTH INDICATIONS RADIATING FROM THE TAPERED PIN ON THE STARBOARD SIDE OF THE CONTROL ARM. INDICATIONS CONTINUED TO APPEAR AFTER REPEATED SURFACE POLISHING AND DYE PENTRANT, ALTHOUGH NO DEFINITIVE. OTHER DEFECTS AND/OR INDICATIONS OBSERVED. INDICATIONS MAY NOT ACTUALLY HAVE BEEN A CRACK, THE INTERMITTENT LINES MAY BE OLD SURFACE FLAWS. HOWEVER, IT WAS DECIDED THAT THE BEST COURSE OF ACTION WAS TO REPLACE PART. OLD PART DID HAVE THE SMALLER AN 386-3-18 TAPERED PINS, INSTEAD OF THE LARGER, AN 386-5-18 PINS USED ON THE LATER MFG ELEVATOR CONTROL ARMS, THIS MAY HAVE BEEN A CONTRIBUTING FACTOR, DUE TO SMALLER HOLE RADIUS AND/OR EXCESSIVE INSTALLATION TORQUE. (K)

CA070724005

BELL  

LYC  

 

CONTROL LEVER

BROKEN

7/23/2007

205A1

T5317A

 

204060765007

ENGINE

(CAN) THIS IS THE INITIAL REPORT. INFORMATION NOT HERE YET. THE PILOT COULD ONLY GET 92 PERCENT NR RP, LANDED THE AIRCRAFT NO INCIDENT, AFTER SHUTDOWN THE ENGINEER OPENED THE GOVERNOR SIDE ENGINE COWLING AND FOUND THE THE GOVERNOR LEVER BROKEN BOTH ENDS OF THE LEVER OR ARM WERE SECURE AND SAFETY. WE ARE STILL INVESTIGATING. (TC NR 20070724005)

2007FA0000636

BELL  

ALLSN

 

BLADE

DEPARTED

7/1/2007

206B

250B*

 

206016201127M

TAIL ROTOR

THE CENTER TIP WEIGHT SLUNG OUT OF SUBJECT TAIL ROTOR BLADE DURING FLIGHT, CAUSING A VIOLENT VIBRATION. THE VIBRATION CAUSED (3) OF THE TAIL ROTOR GEAR BOX STUDS TO SHEAR BEFORE THE AIRCRAFT COULD AUTO ROTATE TO THE GROUND. IF THE HELICOPTER HAD NOT MADE IT TO THE GROUND WHEN IT DID THE OTHER STUD WOULD HAVE SHEARED AND THE TAIL ROTOR GEAR BOX WOULD HAVE LEFT THE AIRCRAFT AND THE RESULTS WOULD HAVE BEEN DISASTROUS. RECOMMEND THE TIP BLOCKS BE MFG FROM MATERIAL THAT CAN WITHSTAND THE CENTRIFUGAL FORCES THAT ARE APPLIED TO THE TIP WEIGHTS DURING FLIGHT. RECOMMEND THAT HELICOPTER TAIL ROTOR BLADE TIPS BE INSPECTED AS SOON AS POSSIBLE AND EVERY 100 HR INSPECTION. (K)

2007FA0000692

BELL  

ALLSN

 

RIB  

CRACKED

7/6/2007

206B

250C20

 

206020123048

TAIL BOOM

DURING THE COURSE OF A SCHEDULED INSPECTION, THE RT HORIZONTAL STABILIZER WAS REMOVED TO TROUBLESHOOT A PROBLEM WITH AN AUXILIARY STROBE LIGHT THAT IS ATTACHED TO THE STABILIZER. DURING REMOVAL, THE FLANGE ON THE IB RIB THAT ATTACHES THE STABILIZER TO THE TAILBOOM WAS FOUND CRACKED AND SEPARATED INTO 2-PIECES. DUE TO THE LOCATION OF THE CRACK IT WAS NOT VISIBLE WITH THE STABILIZER INSTALLED. (K)

CA070724006

BELL  

ALLSN

 

ENGINE

OVERHEATED

7/23/2007

206B

250C20

 

 

 

(CAN) THE PILOT HAD JUST TAKEN HIS FINGER OFF THE THE STARTER ON STARTUP AND WAS REVIEWING HIS COMPANY PILOT MINI LOG WHEN HE NOTED A DIFFERENT ENGINE SOUND AS THOUGH IT HAD INCREASED. WHILE CHECKING THE THROTTLE AND SCANNING THE GAUGES THE PILOT NOTICED THAT THE TOT WAS AT 1000 DEGREES. THE ENGINE ASSEMBLY WAS REPLACED. (TC NR 20070724006)

CA070622005

BELL  

ALLSN

 

INDICATOR

DEFECTIVE

6/21/2007

206B

250C20

 

EA4703587

FUEL QTY

(CAN) FUEL QUANTITY INDICATOR WAS REMOVED DUE TO INDICATION PROBLEMS. WHEN REMOVED IT WAS FOUND THAT THE FLOAT WAS FULL OF FUEL AND ONE OF THE DECALS FROM PHP WAS GONE AND WAS IN THE FUEL SYSTEM. DECAL WAS LOCATED AND SENDER IS BEING REPLACED WITH A NEW UNIT. (TC NR 20070622005)

CA070706004

BELL  

ALLSN

 

FUEL CONTROL

UNSERVICEABLE

7/5/2007

206L1

250C28

 

23065144

ENGINE

(CAN) FUEL CONTROL WAS INTERMITTENT ON ENGINE LIGHT-OFF DURING A START. FUEL CONTROL CHANGED OUT. (TC NR 20070706004)

CA070706002

BELL  

ALLSN

RROYCE

SCROLL

WARPED

7/5/2007

206L1

250C28

 

23056109

COMPRESSOR

(CAN) DURING A GROUND RUN AN AIR LEAK WAS FOUND AT THE SCROLL DIFFUSER SPLIT LINE. COMPRESSOR ASSY WAS CHANGED OUT. (TC NR 20070706002)

CA070718005

BELL  

ALLSN

 

COMBUSTION LINER

CRACKED

7/15/2007

206L1

250C30P

 

6899081

ENGINE

(CAN) COMBUSTION LINER REMOVED AND INSPECTED DURING UN-RELATED ENGINE MAINTENANCE. FOUND CRACKED AND WARPED BEYOND LIMITS. (TC NR 20070718005)

CA070626001

BELL  

 

 

HOSE

DEBONDED

6/22/2007

206L4

 

 

206063607101

FUEL SYSTEM

(CAN) FUEL HOSE ASSY DEBONDED CAUSING FUEL LEAK FROM FWD TANKS. THE RUBBER BELLOW PART OF THE TUBE ASSEMBLY DEBONDED FROM THE ALUMINUM TUBING. THIS HOSE ASSEMBLY IS LOCATED ON THE LT SIDE FWD FUEL TANK. REFER TO HELICOPTER IPB FIGURE 28-3 ITEM NR 57. (TC NR 20070626001)

AOC0701

BELL  

PWA  

 

BEARING

DAMAGED

8/16/2007

412  

PT6T3B

 

 

PITCH LINK

DURING A PREFLIGHT INSPECTION OF THE SUBJECT AIRCRAFT, A PITCH CHANGE LINK BEARING (ATTACHED TO THE DRIVER END) APPEARED TO BE WORN. THE PILOT ATTEMPTED TO MOVE THE DRIVER TO CHECK FOR WEAR BUT THE BEARING, BOLT AND DRIVER WERE TIGHT. THE PILOT THEN OBSERVED THE BEARING WHILE THE OTHER PILOT PULLED SLIGHTLY UP ON THE COLLECTIVE CONTROL. AS THIS OCCURRED, THE PILOT FOUND THAT THE BOLT AND BEARING WERE MOVING APPROXIMATELY .1875 INCH. FURTHER INSPECTION REVEALED THAT THE STEEL BUSHING ON THE DRIVER, TRAILING (NUT) SIDE, WAS WORN DOWN CONSIDERABLY (.0001 - .0002 INCH OF STEEL REMAINING). HAD THIS BEEN ALLOWED TO CONTINUE, THE BOLT WOULD HAVE STARTED TO WEAR INTO THE SOFTER METAL OF THE DRIVER, EVENTUALLY CAUSING LOSS OF CONTROL OF THE HELICOPTER. THE PILOT HIGHLY RECOMMENDS THAT THESE BEARINGS BE INSPECTED AFTER THE APPLICATION OF SLIGHT UPWARD PRESSURE TO THE COLLECTIVE CONTROL SO THE BEARINGS ARE NOT PRE-LOADED.

2007FA0000678

BLANCA

CONT

 

SHUTTLE VALVE

MALFUNCTIONED

6/24/2007

1730A

IO520K

 

1956750

MLG 

THE AIRCRAFT LOST ELECTRICAL POWER AND PILOT TRIED TO EXTEND THE LANDING GEAR USING THE EMERGENCY LEVER. THE EMERGENCY LOWERING OF THE LANDING GEAR DID NOT TAKE PLACE AND THE PILOT HAD TO LAND THE AIRCRAFT WITH THE LANDING GEAR IN THE FULL UP POSITION. DAMAGE; PROP STRIKE, LOWER FUSELAGE SKIDDING DAMAGE, LOWER FUSELAGE FUEL DRAIN GROUND OFF, SUDDEN STOPPAGE OF THE ENGINE.

2007FA0000687

BLANCA

LYC  

 

POWERPACK

BURNED OUT

7/24/2007

1731A

IO540K1E5

 

105932B

MLG 

THIS COMPONENT WAS INSTALLED FRESHLY OVERHAULED ON APRIL 6, 2006 AND HAS A TOTAL IN USE TIME OF 18.0 HOURS. AFTER TAKEOFF THE PILOT NOTICED THE LANDING GEAR WOULD NOT RETRACT. TROUBLESHOOTING OF THE LANDING GEAR SYSTEM FINDS THE HYDRAULIC POWER PACK MOTOR WINDINGS ARE OPEN, MOTOR WILL NOT RUN. UNIT WAS OVERHAULED UNDER WO NR AH-16326. (K)

CA070202008

BNORM

LYC  

 

COLLAR

BROKEN

1/30/2007

BN2A26

O540E4C5

 

NB046547R

NLG STEERING

(CAN) NOSE LANDING GEAR STEERING COLLAR, BROKE IN TWO PIECES DURING GROUND HANDLING. COLLAR CRACKED AFT GREASE FITTING HOLE ANF FWD RT RELEASE DOG SLOT. (TC NR 20070202008)

CA070717017

BOEING

PWA  

 

NUT  

LOOSE

7/3/2007

727225

JT8D15

 

NAS679A3W

TE FLAPS

(CAN) ON APPROACH, CREW SELECTED FLAPS FROM 2 TO 5 AND HAD AN AMBER LIGHT INDICATION FOR THE NR 1 KRUGER FLAP INDICATING STILL RETRACTED. FELT MODERATE VIBRATION AND DECLARED AN EMERGENCY. UNEVENTFUL LANDING. MAINTENANCE CYCLED SYSTEM AND COULD NOT FAULT. FURTHER INSPECTION FOUND THE NR 1 KRUGER FLAP SWITCH LINK BOLT/NUT LOOSE. (TC NR 20070717017)

CA070727004

BOEING

PWA  

 

FITTING

DAMAGED

7/25/2007

727243

JT8D9A

 

 

GEARBOX OIL

(CAN) TOP OF DESCENT, THE NR 1 LOW OIL PRESSURE LIGHT ILLUMINATED, QTY AT ZERO. PRECAUTIONARY ENGINE SHUTDOWN CARRIED OUT. GEARBOX FITTING (OIL PRESSURE DIFFERENTIAL SWITCH) THREAD REPAIRED AND FITTING REPLACED. ENGINE INSPECTEED IAW MM AND RETURNED TO SERVICE. (TC NR 20070727004)

CA070801002

BOEING

CFMINT

 

ENTERTAIN SYS

SMOKE

7/31/2007

737*

CFM567B22

 

3088510101

CABIN

(CAN) WHILE LOADING THE AFT BAGGAGE PIT, A BURNING ELECTRICAL ODOR AND SMOKE WERE NOTICED AND TRACED TO THE LIVE-TV ELECTRICAL RACK COMPONENT WIRELESS AIRCRAFT UNIT. POWER WAS REMOVED FROM THE AIRCRAFT AND THE WIRELESS AIRCRAFT UNIT WAS REMOVED. THIS COMPONENT WILL BE RETURNED TO THE MFG AND A COMPLETE TEARDOWN REPORT WILL BE REQUESTED. THIS SDR WILL BE UPDATED ONCE THAT INFORMATION IS AVAILABLE. (TC NR 20070801002)

CA070703006

BOEING

GE  

 

CONTROL PANEL

DAMAGED

7/2/2007

737*

CFM567B24

 

4739551

FIRE CONTROL

(CAN) ON JULY 2/07 IN PREPARATION FOR THE DAYS FLYING THE CREW REPORTED THE CARGO FIRE BELL SOUNDING. THE FORWARD CARGO FIRE C/BS WERE FOUND POPPED AND SMOKE WAS COMING FROM THE FLIGHT DECK CARGO FIRE DETECTOR PANEL. THIS RESULTED IN THE FWD CARGO PIT EXTINGUISHER DISCHARGING ITSELF. THE FIRE PANEL MODULE AND THE DEPLETED FIRE BOTTLE WERE REPLACED. THE OEM TO WHICH THE DAMAGED PANEL WAS SENT HAS BEEN REQUESTED TO INVESTIGATE, PROVIDE A DETAIL STRIP REPORT AND PHOTOS. FURTHER INFORMATION WILL BE SUBMITTED AT THE CONCLUSION OF THIS INVESTIGATION. (TC NR 20070703006)

SROM200700006

BOEING

PWA  

 

FRAME

CRACKED

8/1/2007

737205

JT8D17

 

 

BS 616

NR63-CRACK ON BODY FRAME INNER CHORD BS616 RT SIDE AT STUB BEAM LOWER CHORD ATTACH (ABOVE WING BOX BL64R). DAMAGE OF BODY FRAME INNER CHORD STA 616 RT SIDE AT STUB BEAM LOWER CHORD ATTACH REMOVED IAW MFG SB 737-53-1182R1. REPAIR ANGLE INSTALLED IAW MFG SB 737-53-1182R1 AND MFG MSG NR: 1-508321689-2.

SROM200700019

BOEING

PWA  

 

SKIN

NICKED

8/18/2007

737205

JT8D17A

 

 

ZONE 100

NICK STA 887 STR 24L-25L LT. DAMAGED AREA OF SKIN REMOVED AND REPAIR PLATES FABRICATED IAW SRM 53-30-3, FIG 48. INSTALLED REPAIR IAW 51-30-2.

SROM200700014

BOEING

PWA  

 

FLOORBEAM

CORRODED

8/10/2007

737205

JT8D17A

 

 

ZONE 100

NR296-CORROSION ON FLOORBEAM UPPER FLANGE AT STA 294 AND RBL 43 TO 53. FLOORBEAM UPPER FLANGE FROM RBL 6 (EXISTING SPLICE) TO RBL 60, STA 294 REMOVED AND REPLACED IAW WITH MFG SRM 53-10-9, FIG 5, SHEET 1-5.

SROM200700018

BOEING

PWA  

 

SKIN

NICKED

8/18/2007

737205

JT8D17A

 

 

BS 907

NICK STA 907 STR 22 LT. NICK AT STA 907, STR 22L REPAIRED IAW SRM 53-30-3, FIG 48. NICK BEYOND LIMITS AND DAMAGE REMOVED. HFEC IAW NDT PART 6, 53-30-00, FIG 4 OF REPAIR AT FUSELAGE SKIN STA 907 STR 22L. NO CRACKS EVIDENT.

SROM200700022

BOEING

PWA  

 

FRAME

CORRODED

8/3/2007

737205

JT8D17A

 

 

BS 783 S25R

NR145-LIGHT CORROSION ON FRAME AT STA 783 STR 25R. REPAIRED FRAME IAW MFG MESSAGE NR 1-518342007-2, DATED AUG 1, 2007 AND PRODUCTION DRAWINGS FOR PN 65-47959-47 STRAP AND PN 65C31240-1 FRAME DOUBLER.

SROM200700007

BOEING

PWA  

 

FLOORBEAM

CRACKED

8/7/2007

737205

JT8D17A

 

 

BS 660

NR228-CRACK IN FLOORBEAM AND WEB STA 660 BL0. CRACKED FLOORBEAM AND WEB AT STA 660 BL0 REPAIRED IAW MFG SB 737-57-1210, REV 1, DATED AUG 27/07.

SROM200700020

BOEING

PWA  

 

SKIN

NICKED

8/18/2007

737205

JT8D17A

 

 

ZONE 100

NICK STA 847 STR 21 LT. NICK AT STA 847 STR 21L FOUND TO BE BEYOND LIMITS. NICK REMOVED AND AREA AT STA 847 STR 21L REPAIRED IAW SRM 53-30-3, FIG 48.

SROM200700021

BOEING

PWA  

 

FLOORBEAM

CORRODED

8/10/2007

737205

PT6A114A

 

 

BS 328

NR392-CORROSION ON UPPER CHORD OF FLOORBEAM STA 328 RBL 52. FLOORBEAM REPAIRED IAW SRM 53-10-9, FIG 5, PAGE 21.

2007FA0000704

BOEING

GE  

 

LINE

LEAKING

8/9/2007

7373T0

CFM563B1

 

 

FUEL CONTROL

FLOAT STICKS, CAUSING FUEL TO COME OUT OF CARBURETOR SPLIT LINE. LEAKING FUEL FROM GASKET.

CA070717010

BOEING

CFMINT

 

CONNECTOR

CORRODED

7/3/2007

737800*

CFM567B26US

 

BACC63BV22F55PN

TE FLAPS

(CAN) AFTER FLAP 25 TAKEOFF, WHEN FLAP RETRACTION INITIATED, FLAP ASYMMETRY INDICATED AND TE FLAP SKEW SENSOR CB POPPED. AIRCRAFT RETURNED TO JTR. SFCC BITE TEST CARRIED OUT, MSG 27-51407 INTERMITTENT. FIM TASK 27-51-00-810-848 CARRIED OUT WITH NO FINDINGS. VISUAL CHECK OF SLAT/FLAP SYSTEM CARRIED OUT WITH NO FINDINGS. OVERWEIGHT LANDING INSP CARRIED OUT WITH NO FINDINGS. AC DEPARTED TO DUB. ON APPROACH TO DUB, MACH TRIM LIGHT CAME ON MOMENTARY, FOLLOWED BY NO PITCH COMMANDS ON CAPTAIN`S FD, NO AP A AND MAGENTA IAS INDICATION ON CAPTAIN`S DU. WHEN FLAP SELECTED TO 1, FLAP ASYMMETRY INDICATION OBSERVED AND TE FLAP SKEW SENSOR CB WAS FOUND POPPED. AFTER EXTENSIVE TROUBLESHOOTING A SHORT WAS FOUND IN THE LT TE FLAP SKEW SENSOR WIRING. PIN 11 INSIDE THE CONNECTOR D40024J (REF.B737 WDM 27-53-21) WAS FOUND CORRODED AND SHORTED TO GROUND. CONNECTOR P/N BACC63BV22F55PN REPLACED, ALL DISTURBED SYSTEMS FUNCTION CHECKED SERVICEABLE AND THE AC RETURNED TO SERVICE. THIS WAS A SECOND SIMILAR EVENT. FIRST EVENT, INVOLVING SAME CONNECTOR, OCCURRED ON C-FTAE IN JANUARY 2007 AND IT WAS CONSIDERED AN ISOLATED EVENT AT THAT TIME. SL 737-SL-24-171-B ADVISES OF THE MOISTURE INGRESSION INTO, AMONG OTHERS, WING TRAILING EDGE CONNECTORS, HOWEVER, CONNECTORS D40024 AND D40034 ARE NOT SUBJECTED IN THIS SL. (TC NR 20070717010)

CA070720003

BOMBDR

PWC  

 

HOSE

RUPTURED

7/17/2007

DHC8400

PW150A

 

AE7128852

NLG ACTUATOR

(CAN) DURING SELECTING GEAR UP, THE CAUTION WARNING AND NOSE GEAR INDICATED NOT UP, MAIN GEAR UP. SUBSEQUENTLY NOTED (NR 2 HYDRAULIC SYSTEM ZERO QUANTITY. FLUID LOSS DUE TO DAMAGED HYDRAULIC PIPE IN NLG WELL. REPAIRS COMPLETED, AC RTS. (TC NR 20070720003)

CA070704010

BOMBDR

PWC  

 

BLEED VALVE

FAULTED

5/5/2007

DHC8400

PW150A

 

 

COMPRESSOR

(CAN) ON APPROACH, AN ENGINE FADEC CAUTION LIGHT ILLUMINATED AND THE PILOT ELECTED TO SHUTDOWN THE ENGINE (PRECAUTIONARY). SUBSEQUENT INSPECTION REVEALED A FAULTY INTERCOMPRESSOR BLEED VALVE. (TC NR 20070704010)

CA070712001

BOMBDR

PWC  

 

CONTROLLER

MALFUNCTIONED

7/9/2007

DHC8400

PW150A

 

699018002

NR1 ENGINE

(CAN) DURING CRUISE AT 25,000 FT, THE NR 1 POWERPLANT AND NR 1 PEC (PROP ELECTRONIC CONTROLLER) CAUTION LIGHTS ILLUMINATED. THE NR 1 ENGINE WENT INTO THE AMBER. PILOTS CARRIED OUT AN IN-FLIGHT SHUTDOWN, DECLARED AN EMERGENCY AND RETURNED TO BASE. FAULT CODES 161 AND 157 WERE LOGGED IN THE CDS. PROPELLER ELECTRONIC CONTROL UNIT REPLACED, OVERSPEED GOVERNOR (OSG) FAULTS HAVE BEEN SINCE BEEN CLEARED AND FUNCTIONAL CHECKS HAVE BEEN COMPLETED. (TC NR 20070712001)

CA070717001

BOMBDR

PWC  

 

WIRE

DAMAGED

6/26/2007

DHC8400

PW150A

 

 

EDU 

(CAN) LATE IN THE AIRCRAFT`S LANDING SEQUENCE, THE FLIGHT DECK ENGINE DISPLAY SUFFERED A FAILURE CAUSING THE DISPLAY TO GO BLANK. THE LANDING WAS COMPLETED WITHOUT INCIDENT. ONCE SHUTDOWN ON THE RAMP, THE CREW IDENTIFIED THAT ONE OF THE ESID CIRCUIT BREAKERS WAS (POPPED). FOLLOWING ADVICE FROM ENGINEERING, ATTEMPTS TO RESET THE CIRCUIT BREAKER WERE UNSUCCESSFUL. ON SITE ENGINEERING INVESTIGATION IDENTIFIED THAT BOTH POWER WIRES TO THE EDU WERE DAMAGED DUE CHAFING RESULTING IN A SHORT CIRCUIT TO GROUND. DAMAGED WIRES WERE REPAIRED IAW MM PROCEDURES. IT WAS ESTABLISHED THAT THE WIRE CHAFING WAS DUE TO INCORRECT FACTORY INSTALLATION OF THE WIRING LOOM EDU CONNECTOR BACKSHELL WHICH IN TURN ALLOWS THE LOOM WIRES TO CHAFE AGAINST INSTRUMENT PANEL STRUCTURE ONCE EDU IS INSTALLED. LOOM CONNECTOR BACKSHELL WAS INSTALLED 180 DEGREES FROM CORRECT POSITION. BACKSHELL WAS POSITIONED CORRECTLY AS PART OF THE WIRE REPAIRS. AS A RESULT OF THE DEFECT AND FINDING A FLEET INSPECTION HAS BEEN INSTIGATED TO ENSURE CORRECT BACKSHELL INSTALLATION. (TC NR 20070717001)

CA070709004

BOMBDR

PWC  

 

TIRE

FAILED

7/6/2007

DHC8400

PW150A

 

DR7622T

MLG 

(CAN) LT INNER TIRE BLOWN AFTER TAKEOFF. UNSCHEDULED LANDING CARRIED OUT. A/C TOWED TO HANGER. INSPECTION AND NR 1 AND NR 2 MAINWHEELS REPLACED. TIRE WAS A RETREAD R2. (TC NR 20070709004)

CA070710002

BOMBDR

PWC  

 

OXYGEN MASK

INOPERATIVE

6/15/2007

DHC8400

PW150A

 

17426008

COCKPIT

(CAN) F/O`S OXYGEN MASK WHEN DONED, WEARER COULD NOT EXHALE WHEN BREATHING. ENGINEERING INVESTIGATION INDICATES THAT THE MASK EXHALE VALVE IS DEFECTIVE. MASK REPLACED. AIRCRAFT RETURNED TO SERVICE SATISFACTORY. MASK HAS BEEN RETURNED TO THE MANUFACTURER FOR REPAIR AND WITH A REQUEST FOR A STRIP REPORT. (TC NR 20070710002)

CA070710003

BOMBDR

PWC  

 

PSEU

INOPERATIVE

5/31/2007

DHC8400

PW150A

 

301450301

PROXIMITY SENSOR

(CAN) ON DEPARTURE CLIMBING THROUGH 9000 FT, THE ENGINE DISPLAY POWERPLANT ADVISORY ILLUMINATED. FOLLOWING DISCUSSIONS WITH BASE ENGINEERING THE CREW DECIDED TO RETURN THE AIRCRAFT TO BASE WHERE AN APPROACH AND LANDING WAS CARRIED OUT WITHOUT INCIDENT. THE POWERPLANT ADVISORY FAULT CODE 338 IS THE 3RD OCCURRANCE ON THIS AIRCRAFT. FOLLOWING ADVICE FROM THE MFG AND DETAILED TROUBLESHOOTING THE AIRCRAFT`S PSEU WAS REPLACED. AIRCRAFT WAS RELEASED BACK TO SERVICE WHERE IT HAS OPERATED SINCE WITHOUT INCIDENT. (TC NR 20070710003)

CA070712002

BRAERO

RROYCE

 

LINE

PERFORATED

7/10/2007

HS7482A

DART5342

 

TC2500065500

HYDRAULIC SYS

(CAN) AFTER DEPARTING, THE CREW OBSERVED BOTH THE LT AND RT HYDRAULIC PRESSURE LOSS INDICATION LIGHTS WERE ILLUMINATED. THE AIRCRAFT DIVERTED AND LANDED WITHOUT FURTHER PROBLEM. MAINTENANCE FOUND THE NR 2 HYDRAULIC PRESSURE RETURN LINE TO THE HP FILTER IN THE WHEEL WELL PERFORATED DUE TO CONTACT WITH A BROKEN CLAMP WHICH SUPPORTS THE GENERATOR COOLING BLEED AIR LINE. BOTH ITEMS WERE REPLACED AFTER WHICH THE AIRCRAFT WAS SATISFACTORILY GROUNDED AND RETURNED TO SERVICE. FIRST AIR CONDUCTED A CHECK OF THE REMAINING SAME TYPE AIRCRAFT OPERATED AND FOUND NO SIMILAR CONDITION PRESENT. (TC NR 20070712002)

CA070717009

CESSNA

CONT

 

BRACKET

BROKEN

5/12/2007

120  

C8512F

 

 

SPINNER

(CAN) V-BRACKET OF SPINNER BROKE ON ONE SIDE, THAT CAUSED OFFSET OF SPINNER WHICH CAUSED VIBRATION AND DECIDED TO CONDUCT A PRECAUTIONARY LANDING ON A FARMERS FIELD. NO FURTHER DAMAGE. (TC NR 20070717009)

CA070405003

CESSNA

CONT

 

BELLCRANK

CRACKED

2/15/2007

150  

O200A

 

04310031

RUDDER

(CAN) FOLLOWING ITEMS FOUND INSTALLED: TRIANGLE DOUBLERS IAW SL 150-27; ANGLE STIFFENER NOT INSTALLED IAW SL 65-10. ANGLE STIFFENER MIGHT BE INSTALLED IAW PERSONAL PLANE SERVICE LTD (OTTAWA). DRAWING NR PPS.161. HAVE NOT BEEN ABLE TO FIND A COPY OF PPS 161, AT THIS TIME (MARCH 29, 2007). IF CRACKED PART IS A NON CONFORMING PART, NO FURTHER ACTION IS NEEDED. MY CONCERNS IS THIS: IF PART IS IAW PPS 161, AND NO FURTHER ACTION IS REQUIRED AFTER INSTALLATION (A VERY LONG TIME AGO) AND THEY ARE CRACKING IN SERVICE IT COULD BE QUITE SERIOUS, IN MY OPINION TO LOSE RUDDER CONTROL. THE AREA IN QUESTION IS ALSO VERY DIRTY AND HARD TO LOOK AT DUE TO OIL ACCUMULATION AND DIRT. (TC NR 20070405003)

2007FA0000700

CESSNA

LYC  

 

FORK

CRACKED

7/11/2007

152  

O235*

 

04425037

NOSE GEAR

DURING INSPECTION, FOUND NOSE GEAR FORK CRACKED (1.5 INCH LONG) ON LT UPPER RADIUS OF FORK. AIRCRAFT IS USED FOR TRAINING. (K)

2007AP080901

CESSNA

LYC  

 

SPAR

CRACKED

8/9/2007

152  

O235L2C

 

043200185

RT ELEVATOR

RT ELEVATOR SPAR FOUND BROKEN/CRACKED AT OB ATTACH POINT. OB HINGE BRACKET PULLED AWAY FROM SPAR.

CA070223008

CESSNA

LYC  

 

TUBE

FAILED

2/14/2007

152  

O235L2C

 

0923150

MAIN TIRE

(CAN) THE PILOT REPORTED A FLAT TIRE ON THE RUNWAY. MAINTENANCE REMOVED THE AIRCRAFT FROM THE RUNWAY. FOUND NO DAMAGE TO THE TIRE, THE TUBE WAS FOUND SPLIT IN TWO PLACES AROUND THE OUTER CIRCUMFERENCE. PART HAD BEEN INSTALLED APPROX 1000 HOURS AND APPROX 15 MONTHS. REPLACED THE TUBE AND TIRE AND RETURNED TO SERVICE. (TC NR 20070223008)

CA070508004

CESSNA

LYC  

 

CONTROL SWITCH

FAULTY

4/11/2007

152  

O235L2C

 

S19061

TE FLAPS

(CAN) DURING CIRCUITS, PILOTS SELECTED FLAPS UP AND THEY REMAINED IN THE FULL DOWN POSITION. FOUND UP CONTROL SWITCH AT FLAP SELECTOR IN COCKPIT FAULTY, REPLACED SWITCH, OPS CHECKED OK WITH NO FURTHER OCCURANCES. (TC NR 20070508004)

CA070131006

CESSNA

LYC  

 

SKIN

CRACKED

9/29/2006

152  

O235L2C

 

 

WING 

(CAN) 2 CRACKS WERE DETECTED ON THE WING SKIN JUST UNDER THE LEADING EDGE ON BOTH WINGS. THE WING ATTACHMENT FITTINGS OF THE AIRCRAFT WERE INSPECTED AND NO FURTHER CRACKS WERE DISCOVERED. THE WINGS WERE REMOVED TO CONDUCT A MORE DETAILED EXAMINATION AND THE AMO IS IN CONTACT WITH MFGV FOR REPAIR INSTRUCTIONS. (TC NR 20070131006)

CA070214003

CESSNA

LYC  

 

SPAR

CRACKED

11/18/2005

152  

O235L2C

 

043200156

HORIZONTAL STAB

(CAN) DURING 100 HOUR INSPECTION, VERIFICATION OF AD 80-11-04, THE TECHNICIAN FOUND A CRACKED BRACKET. CLOSER INSPECTION INDICATED THAT THE SPAR WAS ALSO CRACKED. (TC NR 20070214003)

CA070419005

CESSNA

LYC  

 

BRACKET

CRACKED

4/12/2007

172D

O360A1A

 

05310181

RUDDER

(CAN) DURING THE ANNUAL INSPECTION, BOTH RUDDER HINGE BRACKETS WERE FOUND TO BE CRACKED. RUDDER WAS REMOVED AND REINSTALLED AFTER REPAIRS. PN 0531018-1 AND 0531018-2 WERE REPLACED WITH NEW IAW THE MM. (TC NR 20070419005)

CA061124008

CESSNA

LYC  

 

SUPPORT

CRACKED

11/24/2006

172K

O320E2D

 

0541121497

MLG 

(CAN) AIRCRAFT BEING SERVICED FOR MFG CARE NR 4 (200-HOUR) INSPECTION AND CHANGED OVER TO SKIS. LT OB SUPPORT FOR LANDING GEAR WAS FOUND TO HAVE SEVERAL CRACKS. PART WAS REPLACED WITH NEW. AIRCRAFT IS OPERATED AS FLOATPLANE AND SKIPLANE FOR FLIGHT TRAINING. (TC NR 20061124008)

CA070727006

CESSNA

LYC  

 

WEB  

CRACKED

7/23/2007

172K

O320E2D

 

 

ENGINE MOUNT

(CAN) CRACK FOUND AT LOWER WELD WEB LT SIDE. (TC NR 20070727006)

2007FA0000689

CESSNA

LYC  

 

CIRCUIT BREAKER

FAILED

7/1/2007

172M

O320*

 

S159660L

COCKPIT

PILOT STATED SMOKE IN COCKPIT. INSPECTION REVEALED ALTERNATOR OUTPUT C/B FAILED, ALTERNATOR HAD BROKEN AND LOOSE PARTS INTERNALLY, AND VOLTAGE REGULATOR FAILED. OPENED C/B AND FOUND INTERNAL PARTS HAD MELTED CAUSING SMOKE. NO SIGNS OF WIRE OVERHEATING, OR SECONDARY DAMAGE WAS FOUND. (K)

CA070718006

CESSNA

LYC  

 

BULKHEAD

CRACKED

6/27/2007

172M

O320E2D

 

05120151

FUSELAGE

(CAN) DURING THE 200 HOUR INSPECTION, A ONE-INCH CRACK WAS NOTED RUNNING HORIZONTALLY ACROSS THE FLANGE BEND RADIUS AT THE LOWER LT CORNER OF THE BULKHEAD. A SMALL DENT WAS NOTED AT THIS POINT, PROBABLY EXISTING SINCE MFG, STRESSING THE ALUMINUM AND TIGHTENING THE BEND RADIUS SOMEWHAT. THIS AREA CAN BE FELT TO FLEX SLIGHTLY WHEN THE TAIL IS MANUALLY MOVED SIDEWAYS. (TC NR 20070718006)

CA070423006

CESSNA

LYC  

 

SEAT

CRACKED

4/19/2007

172M

O320E2D

 

05142043

COCKPIT

(CAN) WHILE PERFORMING AD CF87-15R2 A CRACK WAS NOTED IN THE RADIUS OF THE MACHINED FORK AT THE LT FRONT LOCATION. THE FORK IS MADE OF RATHER THIN RECTANGULAR ALUMINUM TUBING AND IS SUBJECT TO SOME FLEXING AS OCCUPANTS ENTER OR EXIT THE AIRCRAFT. (TC NR 20070423006)

2007FA0000647

CESSNA

LYC  

 

PISTON

CRACKED

7/20/2007

172M

O360A4M

 

AE75089

NR 2 CYLINDER

PISTON SKIRT CRACKED ON 2 CYLINDERS.

CA070802005

CESSNA

LYC  

 

BULKHEAD

CRACKED

7/26/2007

172N

O320D2J

 

05503214

SPINNER

(CAN) THIS AIRCRAFT HAS HAD ALL THE AFT BULKHEAD AND HEAVIER SPINNER UPGRADES AND HAS HAD IT ALL ASSEMBLED IAW THE LATEST SB. CRACKS WERE FOUND FORMING PARALLEL FROM THE PROP BOLT HEAD CONTACT SURFACE ON (3) OF THE (6) HOLES. HAVE TO LOOK VERY CAREFULLY AS THE CRACKS RADIATING FROM THE PROP BOLT HOLES ARE VERY FINE AND HIDE UNDER THE FACTORY PRIMER. THE TORQUE OF THE PROP BOLTS IS SHEAR STRESSING THE BULKHEAD. A COVER PLATE IS NEEDED TO OFFSET THE BOLTS FROM THE THIN ALUMINUM SHEET METAL BULKHEAD. THIS PROBLEM IS CONSTANTLY RE-OCCURRING WITH THIS SPINNER ASSY. (TC NR 20070802005)

CA070802006

CESSNA

LYC  

 

CYLINDER

CRACKED

7/24/2007

172N

O320D2J

 

LW12416

ENGINE

(CAN) (2) CRACKS FOUND DURING ENGINE ON-CONDITION INSPECTION. CRACKS START FROM BOTTOM SPARK PLUG HOLE AND EACH CRACK GOES TO A VALVE SEAT. THESE CRACKS WERE NOT DETECTED DURING DIFFERENTIAL PRESSURE INSPECTION OR LEAK TEST. INTERNAL BORESCOPE INSP WAS DETECTION METHOD IAW LATEST B041. (TC NR 20070802006)

CA070717016

CESSNA

LYC  

 

ELT  

INTERMITTENT

7/5/2007

172N

O320H2AD

 

C5895120103

CABIN

(CAN) EARLY ACTIVATION. SELF-ACTIVATION REPORTED TWICE. (TC NR 20070717016)

CA070622002

CESSNA

LYC  

 

ENGINE

LEAKING

6/20/2007

172N

O320H2AD

 

O320H2AD

LEFT 

(CAN) OIL LEAKING FROM FRONT LT AREA OF ENGINE. (TC NR 20070622002)

CA070215004

CESSNA

LYC  

 

ALTERNATOR

MALFUNCTIONED

2/10/2007

172N

O320H2AD

 

10300B

ENGINE

(CAN) ON CLIMB OUT A LOW VOLTAGE LIGHT INDICATION. PILOT RECYCLED ALTERNATOR, LOW VOLTAGE INDICATION WAS NOT CORRECTED AND PILOT RETURNED FOR LANDING (TC NR 20070215004)

CA070717011

CESSNA

LYC  

 

ARM  

BENT

6/21/2007

172N

O360A1F6

 

21A05000016

FLOATS

(CAN) ON ROLL OUT AFTER LANDING THE RT MAIN LANDING GEAR COLLAPSED. INVESTIGATION FOUND THAT THE ACTUATING CYLINDER BENT (P/N D68194-A-4). FURTHER INVESTIGATION FOUND THE RETRACT ARM P/N 21A05000-016 HAD WORN ELONGATED BOLT HOLES NOT ALLOWING A DOWN LOCK OVER CENTRE POSITION. (TC NR 20070717011)

CA070704007

CESSNA

LYC  

 

BULKHEAD

CRACKED

7/4/2007

172P

O320D2J

 

05503214

PROPELLER

(CAN) BULKHEAD IS CRACKED AROUND SEVERAL OF THE PROP THROUGH BOLT HOLES. (TC NR 20070704007)

CA070704008

CESSNA

LYC  

 

BULKHEAD

CRACKED

5/17/2007

172P

O320D2J

 

05503214

SPINNER

(CAN) CRACKED AROUND SEVERAL OF THE PROP BOLT THROUGH HOLES. (TC NR 20070704008)

CA070711005

CESSNA

LYC  

 

SEAT

CRACKED

7/11/2007

172P

O320D2J

 

05142031

COCKPIT

(CAN) DEFECT REPORTED IN THE JOURNEY LOG BOOK THAT RT SEAT WOULD NOT ADJUST. REMOVED SEAT, INSPECTED, AND FOUND THE SEAT BOTTOM FRAME CRACKED COMPLETELY IN (2) PIECES. AREA IS DIFFICULT TO INSPECT BECAUSE OF UPHOLSTERY INSTALLATION. LOWEST TIME IN THE FLEET. (TC NR 20070711005)

2007FA0000658

CESSNA

LYC  

CESSNA

VENT

OBSTRUCTED

6/12/2007

172P

O320D2J

 

052355912

LT WING TANK

ENGINE QUIT IN FLIGHT WITH HALF TANK OF FUEL REMAINING. UPON VISUAL INSPECTION OF LT WING, FOUND THE FUEL VENT LINE PN 052355912 OBSTRUCTED WITH INSET REMAINS (WASP). PHYSICALLY REMOVED OBSTRUCTION AND OPS TESTED ENGINE ON ALL TANK SETTINGS. UPON SUCCESSFUL OPS CHECK OF FUEL SYSTEM, MADE LOG ENTRY AND RETURNED THE AIRCRAFT TO SERVICE. AIRCRAFT HAS SUCCESSFULLY FLOWN 50 HRS SINCE 6/12/07 WITH NO FURTHER INCIDENT.

CA070517003

CESSNA

LYC  

 

CONTROL WHEEL

FAILED

12/14/2006

172P

O320D2J

 

0411257

COCKPIT

(CAN) EXCESSIVE PLAY IN (U) JOINT ON LT CONTROL WHEEL. (TC NR 20070517003)

2007FA0000725

CESSNA

LYC  

 

SENSOR

INTERMITTENT

8/8/2007

172R

IO360A1A

 

CS3100

MASTER CNTRL BOX

CURRENT SENSOR INDICATES 60A AND WHEN MASTER IS TURNED ON FUNCTIONS NORMALLY FROM TIME TO TIME, TAP ON UNIT AND IT FLUCTUATES THEN ACTS PROPERLY. (K)

2007FA0000684

CESSNA

LYC  

 

CRANKSHAFT

CORRODED

7/12/2007

172R

IO360L2A

 

 

ENGINE

FOUND CRANKSHAFT TO BE PITTED, LAST INSPECTION WAS DONE BY MFG (4) YEARS AGO. THIS ENGINE HAD HIGH UTILIZATION AND FREQUENT OIL CHANGES. (K)

2007FA0000639

CESSNA

LYC  

 

HOUSING

CRACKED

5/7/2007

172RG

O360*

 

12810013

MLG ACTUATOR

ON A DUAL TRAINING FLIGHT, STUDENT AND INSTRUCTOR HEARD A NOISE WHEN LANDING GEAR WAS RETRACTED. LT LANDING GEAR REMAINED IN A PARTIALLY RETRACTED/ EXTENDED POSITION, UNABLE TO ACTUATE UP OR DOWN. THE LT LANDING GEAR ACTUATOR BODY HAD FAILED (CRACKED) AT THE FWD MOUNTING BOLT HOLE, ALLOWING THE ACTUATOR BORE TO OPEN ENOUGH SO THAT PISTON WOULD NOT ENGAGE THE LANDING GEAR PIVOT SECTOR GEAR SUFFICIENTLY TO MOVE THE LANDING GEAR. (K)

CA070502005

CESSNA

LYC  

 

BULKHEAD

CRACKED

4/10/2007

172RG

O360F1A6

 

24120111

BS 108

(CAN) PARTS WERE CRACKED AT ATTACH POINTS OF WHEEL WELL COVER SKIN 2412011-1 AND BULKHEADS STATION 108 AND 124 AND CRACK ON WHEEL WELL COVER AT RT FRONT CORNER WHERE IT ATTACHES TO BULKHEAD STATION 108. TIEDOWN RINGS ALSO ATTACH IN THIS AREA. (TC NR 20070502005)

2007FA0000665

CESSNA

 

 

PLACARD

INCORRECT

7/26/2007

172S

 

 

 

CABIN

AIRCRAFT WITH AVIONICS: LOCATION OF INTERIOR ELT PLACARD IN BAGGAGE COMPARTMENT INDICATES THAT THE ELT IS BEHIND THE LOWER ACCESS PANEL TO THE AFT FUSELAGE. THAT IS INCORRECT. THE ELT ACCESS IS FROM THE UPPER PANEL. REMOVED PLACARD AND FABRICATED NEW PLACARD AND PLACED IT ON THE UPPER ACCESS PANEL.

2007FA0000718

CESSNA

 

 

FUEL CONTROL

OUT OF LIMITS

8/21/2007

172S

 

 

25765362

ENGINE

DURING PRE TAKEOFF RUN UP, THE MAG DROP (BOTH MAGS) WAS BEYOND LIMITS. THIS AIRCRAFT HAD A RECENT HISTORY OF RICH SERVO OPERATION FOLLOWED BY ADJUSTMENTS, WHICH WOULD NOT STABILIZE. THE SERVO WAS CHANGED. THIS PROBLEM IS COMMON ON MANY OF THE AIRCRAFT IN THIS FLEET AND HAS CAUSED FLEET-WIDE ADJUSTMENTS WHEN SUBSTANTIAL CHANGES IN ATMOSPHERIC TEMPERATURE OCCUR. IN MANY CASES THE SERVO MUST BE CHANGED WITH ONLY A FEW HOURS SINCE NEW.

2007FA0000755

CESSNA

LYC  

 

STARTER

FAILED

8/2/2007

172S

IO360A1A

 

85070213

ENGINE

STARTER WAS INTERMITTENT AND FAILED COMPLETELY. AVERAGE LIFE FOR THE LAST (2) STARTERS HAS BEEN 115 HRS EACH. (K)

2007FA0000719

CESSNA

LYC  

 

FUEL CONTROL

OUT OF LIMITS

8/21/2007

172S

IO360L2A

 

25765362

ENGINE

DURING PRE TAKE OFF RUN UP, THE MAG DROP (BOTH MAGS) WAS BEYOND LIMITS. THIS AIRCRAFT HAD A RECENT HISTORY OF RICH SERVO OPERATION FOLLWED BY ADJUSTMENTS, WHICH WOULD NOT STABILIZE. THE SERVO WAS CHANGED. THIS PROBEM IS COMMON ON MANY OF THE AIRCRAFT IN THIS FLEET AND HAS CAUSED FLEET-WIDE ADJUSTMENTS WHEN SUBSTANTIAL CHANGES IN ATMOSPHERIC TEMPERATURE OCCUR. IN MANY CASES THE SERVO MUST BE CHANGED WITH ONLY A FEW HOURS SINCE NEW.

2007FA0000720

CESSNA

LYC  

 

CONTROL CABLE

FRAYED

8/21/2007

172S

IO360L2A

 

0510105364

AILERONS

DURING A ROUTINE INSPECTION, THE AILERON BALANCE CABLE WAS FOUND BADLY WORN IN THE LT WING AT STATION 71.125. THE CABLE IS DIRECTED OVER A FAIRLEAD AT THIS LOCATION AND TYPICALLY WEARS VERY BADLY AT THIS CONTACT POINT. BECAUSE THE WEAR PATTER IS OVER A STRAIGHT RUN OF CABLE THERE IS NO BENDING OF THE CABLE WHICH WOULD CAUSE THE STRANDS TO FRAY OUTWARD. BECAUSE OF THIS, THE CABLE CAN BE WORN THROUGH MANY STRANDS AND YET APPEAR NORMAL. ONCE THE CABLE IS REMOVED FROM THE AIRCRAFT AND BENT AS SHOWN IN THE AC43.13-1B, PAGE 7-35, FIGURE 7-16, THE BROKEN STRANDS BECOME READILY APPARENT. THIS HAS BEEN AN ISSUE FOR A LONG TIME ON THIS MODEL AIRCRAFT. IF NOT INSPECTED CAREFULLY THE CABLE CAN DETERIORATE TO A DANGEROUS CONDITION, POSSIBLY UNNOTICED.

2007FA0000646

CESSNA

LYC  

 

PUSHROD

BENT

7/19/2007

172S

IO360L2A

 

05232182

AILERON

AILERON PUSHROD WAS FOUND BENT DURING PREFLIGHT. REMOVED PUSHROD AND WENT TO INSTALL NEW ROD AND FOUND THAT ALL FOUR RODS IN STOCK HAD BAD THREADS- PD WAS OVERSIZED.

CA070215001

CESSNA

LYC  

 

SWITCH

SMOKE

2/13/2007

172S

IO360L2A

 

CM358910

LANDING LIGHT

(CAN) LANDING LIGHT SWITCH GAVE OFF ODOR OF SMOKE, WHEN PILOT WENT TO TURN OFF, THE SWITCH WAS HOT AND THE SHUTOFF THE SWITCH WAS REPLACED WITH A NEW UNIT (TC NR 20070215001)

CA070502010

CESSNA

LYC  

 

CONTROL CABLE

FRAYED

4/18/2007

172S

IO360L2A

 

0510105365

AILERONS

(CAN) DURING INSPECTION RT WING AILERON CONTROL CABLES FOUND TO BE FRAYED WITH BROKEN STRANDS AT WING STATION 100 WHERE CABLES TRAVEL ON TOP OF FAIRLEAD PN 0522647-10 CABLES WERE REPLACED WITH NEW UNITS FROM MFG. (TC NR 20070502010)

CA061108004

CESSNA

LYC  

 

HINGE BRACKET

CRACKED

8/28/2006

177B

O360A1F6

 

17121532

RT STAB

(CAN) RT STABILIZER HINGE BRACKET FOUND CRACKED AT FASTENER LOCATION. (TC NR 20061108004)

CA070426007

CESSNA

 

 

CONNECTOR

LEAKING

4/20/2007

177RG

 

 

S217840114

NLG 

(CAN) AIRCRAFT PLANNING ON LANDING WHEN UNDERCARRIAGE LIGHT FAILED TO INDICATED GEAR DOWN AND LOCKED. DECLARED AN EMERGENCY. AFTER SEVERAL ATTEMPTS AT TRYING TO PUMP GEAR DOWN BY HAND THE PILOT GOT A GEAR DOWN AND LOCKED LIGHT. AIRCRAFT LANDED WITH NO EVENT TAKING PLACE. MAINTENANCE LATER FOUND THE NOSE GEAR ACTUATOR HOSE HAD SLID PARTIALLY FROM ITS SWAGED END CONNECTOR AND WAS LEAKING BADLY. HOSE REPLACED. (TC NR 20070426007)

CA070717007

CESSNA

 

 

BOLT

SHEARED

6/23/2007

177RG

 

 

NAS464P6A16

MLG 

(CAN) MAIN GEAR JAMMED ON RETRACTION FROM TAKEOFF. LANDED WITH MAIN GEAR PARTIALLY EXTENDED. (TC NR 20070717007)

2007FA0000634

CESSNA

CONT

 

SUPPORT

CRACKED

5/20/2007

182E

O470R

 

0750288

AIRBOX

MECH DISCOVERED ON A 50 HR INSP, THE SUPPORT COLLAR ON THE AIRBOX MOUNTED TO THE CARBURETOR WAS CRACKED. THIS COULD LEAD TO THE SEPARATION OF THE AIRBOX FROM THE CARBURETOR AND LOSS OF POWER. PN 0750288 WAS REPLACED WITH NEW SUPPORT COLLAR PN 0750288-1 IAW SRM. (K)

2007FA0000637

CESSNA

CONT

 

PISTON

FRACTURED

6/13/2007

182H

O470R

 

SA640518

NR1 CYLINDER

AFTER INSTALLING NEW CYLINDER ASSY SA47006S-A20P WITH NEW PISTON ASSY PN SA640518, WE WERE PERFORMING BREAK IN RUN AT LOW POWER, FIRST AT 800 RPM FOR 2 MIN. SHUTDOWN ENGINE, CLEANED FOULED PLUGS DUE TO OIL IN CYLINDER FROM ASSY. RAN ENGINE AT 1000 RPM FOR 3 MIN. SHUTDOWN AND CLEANED SPARK PLUGS AGAIN. RESTARTED ENGINE AND ADVANCED TO 1200 RPM, THE CYLINDER CLEARED OUT AND THEN STOPPED AFTER A FEW SECONDS. AFTER REMOVING THE OIL PAN AND NR 1 CYLINDER THE PISTON APPEARED TO HAVE FRACTURED ALONG A CASTING FAULT IN THE PISTON PIN BOSS. THE RESULTING DEBRIS BENT THE CAM SHAFT, BROKE BOTH CRANKSHAFT HALVES. (K)

2007FA0000690

CESSNA

CONT

 

BULKHEAD

CRACKED

7/7/2007

182K

O470*

 

07126161

BS 230

DURING INSPECTION OF THE AFT TAILCONE BULKHEAD (STATION 230.187) A CRACK APPROX .375 INCH LONG WAS DISCOVERED. THE CRACK LOCATION WAS ON THE LT SIDE EMANATING FROM THE RUDDER CUTOUT HOLE AND PROGRESSING TOWARD THE BULKHEAD FLANGE. (K)

2007FA0000664

CESSNA

CONT

 

SPRING ASSY

CRACKED

6/28/2007

182R

O470*

 

07416302

AXEL FITTING

DURING NDI OF MAIN LANDING GEAR SPRING ASSY, THE RT FITTING WAS FOUND CRACKED. DURING WFPT FOR ASTM E1417. PART WAS REPLACED WITH A SERVICEABLE UNIT. SUSPECT CRACK WAS DUE TO CORROSION BETWEEN THE SPRING AND ALUMINUM FITTING. (K)

2007FA0000728

CESSNA

CONT

 

ALTERNATOR

SHORTED

7/31/2007

182R

O470U

 

DOFF10300B

 

ALTERNATOR SHORTED, THIS UNIT IS (1) OF (3) REPLACED IN THE LAST MONTHS. (K)

2007FA0000642

CESSNA

LYC  

 

LINE

LEAKING

7/3/2007

182T

IO540*

 

L2891948A

FUEL SYSTEM

FOUND HEAVY FUEL STAIN FROM OIL COOLER NR 5 INTAKE PIPE AND ON FIREWALL APPROVED TO BE NR 5 INTAKE PIPE. FURTHER INSPECTION FOUND NR 5 FUEL INJECTION LINE LOOSE AT INJECTOR. FOUND AND SNUGGED SEVERAL OTHER INJECTOR LINES AT INJECTOR AND FLOW DIVIDER AD-02-01, AD LAST C/W 5-3-07. (K)

2007FA0000691

CESSNA

LYC  

 

ALTERNATOR

FAILED

6/25/2007

182T

IO540AB1A5

 

991059111RX

ENGINE

AC ARRIVED AT 1R4 WITH A FAILED ALTERNATOR. SYSTEM WAS TESTED TO CONFIRM THAT THE ALTERNATOR WAS THE PROBLEM. ON 6/25/07 THE ALTERNATOR IN QUESTION WAS REMOVED FROM THE AC. UPON REMOVING THE ALTERNATOR THE TECHNICAN FOUND THE SAFETY LOCK WIRE FOR THE ALTERNATOR HOUSING HALVES WAS BROKEN AND ONE OF THE FOUR CAP SCREWS WAS MISSING AND THE OTHER (3) WERE LOOSE. THE AC WAS INSPECTED AGAIN TO DETERMINE IF ANY OTHER PART COULD HAVE COME IN CONTACT WITH THE ALTERNATOR TO CAUSE THE SAFETY LOCK WIRE TO BREAK. NO CONFLICTS WERE NOTED DURING THIS INSPECTION. DIGITAL PICTURES HAVE BEEN TAKEN FOR RECORD AND ARE AVAILABLE UPON REQUEST. (K)

CA070502013

CESSNA

CONT

 

CONTROL CABLE

BROKEN

6/3/2006

185A

IO520D

 

051010551

RUDDER CONTROL

(CAN) THE BOLT THAT ATTACHES THE LT FORWARD RUDDER CABLE TO THE RUDDER PEDAL SETUP WAS ORIGINALLY TOO TIGHTLY DONE UP. THE CABLE ATTACHMENT FORK WAS NOT ABLE TO MOVE FREELY ON END, IN THE FORK, AND BREAK UNDER LOAD. (TC NR 20070502013)

2007FA0000651

CESSNA

CONT

 

FUEL CAP

LEAKING

7/22/2007

185F

IO520D

 

 

WING 

FUEL LEAKING FROM BASE OF NEWLY INSTALLED PREMIUM FUEL CAPS. LOCATION ON WINGS IRRELEVANT. LEAK FROM BOTH IB AND OB CAPS. COMPLIED WITH MFG INSTRUCTIONS IAW VENT LOCATION WITHOUT EFFECT. EVIDENTLY NOT UNCOMMON PROBLEM, AS BLOGS ON MFG CLUB FORUM AND PILOTS ASSOC. FORUM WILL ATTEST. MFG SENT NEW O-RINGS, BUT HAVEN'T TRIED THEM. NEVERTHELESS, CAPS SHOULD BE FOOL-PROOF FROM FACTORY. HARDLY AN IMPROVEMENT OVER MY OLD MFG RAISED INLET CAPS.

CA070504007

CESSNA

CONT

 

TUBE

LEAKING

5/7/2007

207  

IO520D

 

7008006

TIRE 

(CAN) AIRCRAFT LANDED, DURING TAXI RT MAIN WHEEL WENT FLAT AIRCRAFT WAS REMOVED FROM RUNWAY WHEEL ASSY REMOVED, TUBE FOUND TO HAVE A PIN HOLE, TUBE REPLACED, AIRCRAFT RETURNED TO SERVICE (TC NR 20070504007)

2007FA0000733

CESSNA

CONT

HARTZL

HUB  

CRACKED

8/10/2007

207  

IO550F

 

PHCC3YF1RF

PROPELLER

HUB, NDI SHOWS RELEVANT INDICATION OF CRACK.(K)

CA070515001

CESSNA

PWA  

 

RELAY

INOPERATIVE

5/14/2007

208  

PT6A114

2C68

MS2774317

FUEL PUMP

(CAN) A/C ABORTED TAKEOFF AUX PUMP LIGHT ON AT HIGH POWER. RELAY REPLACED, A/C GROUND RUN AT HIGH POWER NO FAULT FOUND (TC NR 20070515001)

CA070516002

CESSNA

PWA  

 

EXHAUST DUCT

CRACKED

5/7/2007

208  

PT6A114A

 

2654008205

ENGINE

(CAN) SECONDARY EXHAUST DUCT CRACKED ALONG THE SEAM ON THE OUTER SIDE FROM ABOUT .2500 THE LENGTH DOWN TO .7500 THE LENGTH, CAUSING SEVERAL SMALLER CRACKS TO FORM ALONG INITIAL CRACK 90 DEGREES FROM THE ORIGINAL BOTH ON THE UPPER AND LOWER SIDES. OTHER OPERATORS REPORTED THAT IT IS NOT UNCOMMON TO HAVE SOME CRACKING. (TC NR 20070516002)

CA070530005

CESSNA

PWA  

 

BOOT

WORN

5/20/2007

208B

PT6A114A

 

SMR517515

DE-ICE SYSTEM

(CAN) DE-ICE BOOT, FOUND WORN RUBBER THAT WAS MELTED FROM EXHAUST GASES. MINOR BLISTERING FOUND ON TOP RT OF BOOT. (TC NR 20070530005)

CA070607006

CESSNA

PWA  

 

HOSE

LEAKING

6/6/2007

208B

PT6A114A

 

AE366372460330

UNKNOWN

(CAN) HOSE PN-AE366372460330 REPLACED DUE TO SHEDULED MAINTENANCE AND LEAK CHECKED SERVICEABLE, AFTER 1.4 HRS AND 4 CYCLES FOUND LEAKING DURING GROUND HANDLING. HOSE REPLACED AND LEAK CHECKED SERVICEABLE (TC NR 20070607006)

CA070705004

CESSNA

PWA  

 

ENGINE

POWER LOSS

5/19/2007

208B

PT6A114A

 

 

 

(CAN) IN CRUISE FLIGHT, THE ENGINE EMITTED A LOUD NOISE AND LOST POWER, RESULTING IN A FORCED LANDING. MFG WILL MONITOR INVESTIGATION OF THE INCIDENT AND REPORT ROOT CAUSE ONCE DETERMINED. (TC NR 20070705004)

CA070410003

CESSNA

CONT

 

BOLT

BROKEN

3/27/2007

210L

IO520L

 

NAS464P4A29

LT MLG ACTUATOR

(CAN) ON SCHEDULED INSPECTION APPRENTICE FOUND ONE ATTACH BOLT BACKED OUT OF HOLE. ON REMOVING THE BOLT FULLY HE FOUND THE BOLT TO BE BROKEN. THE AIRCRAFT WAS JACKED UP AND THE ACTUATOR WAS REMOVED. THE OTHER 2 ATTACH BOLTS WERE INSPECTED AND FOUND WORN. THE ACTUATOR WAS INSPECTED FOR CRACKS. NONE FOUND. THE ATTACH BULKHEAD WAS INSPECTED ALSO. NO FAULTS WERE FOUND. THE ACTUATOR WAS REINSTALLED WITH NEW BOLTS. GEAR WAS SWUNG AND AIRCRAFT RETURNED TO SERVICE. SUSPECT THAT AS THERE ARE NO LOCKING DEVICES OTHER THAN TORQUE, BOLTS LOOSENED OVER TIME AND BOLT BROKE DUE TO GEAR TRANSIT FORCES. (TC NR 20070410003)

CA070511002

CESSNA

CONT

 

TORQUE TUBE

BROKEN

5/10/2007

310R

IO520M

 

504501025

MLG 

(CAN) AFTER TAKE-OFF PILOT RETACTED GEAR ALL 3 GREEN LIGHTS WENT OUT AND UNLOCKED LIGHT WAS OUT. RADIO CALL FROM TOWER INFORMED PILOT THAT LT MAIN GEAR WAS NOT RETRACTED. PILOT PUT GEAR DOWN AND GOT ALL 3 GREEN LIGHTS. SHUT DOWN LT ENGINE IN CASE GEAR COLLAPSED ON LANDING AND MADE UNEVENTFUL LANDING. AIRCRAFT INSPECTED AND IT WAS NOTED THAT THE LT MAIN RETRACT TORQUE TUBE WAS BROKEN. NEW PART ON ORDER. (TC NR 20070511002)

2007FA0000628

CESSNA

CONT

 

NUT PLATE

DAMAGED

7/18/2007

340A

TSIO520*

 

 

SPAR 

WHILE UNDERGOING A ANNUAL INSPECTION INVESTIGATION OF NOISE COMPLAINT FROM THE LANDING GEARBOX IT WAS DISCOVERED THAT THE FOUR AN3-6A BOLTS THAT ATTACH THE PART 5011013-3 (BRACKET ACUATOR MOUNTING) & GEARBOX TO THE FRONT SPAR WAS LOOSE. AN ATTEMPT AT TIGHTEN THEM REVEALED THAT THE NUT PLATES BUILT INSIDE THE SPAR WERE STRIPPED. ALLOWED THE GEARBOX TO MOVE BACK FROM THE SPAR BY 1/8" AND REAR BULKHEAD FLEXING THE 1/8". (FS152.75)

2007FA0000675

CESSNA

CONT

 

SKIN

CRACKED

7/12/2007

340A

TSIO520*

 

08220009

LT WING

CRACK IN THE TOP SKIN OF THE LT WING AT THE LANDING GEAR SIDE BRACE ATTACHMENT LOCATION, APPROXIMATELY WS 63.45. THE SKIN IS 2024-T63 ALUMINUM, .032 THICK. THE CRACK IS ABOUT 3 INCHES LONG OR LONGER. CANNOT DETERMINE THE TOTAL LENGTH OF THE CRACK. (K)

CA061117003

CESSNA

CONT

 

DOUBLER

MISINSTALLED

11/16/2006

340A

TSIO520NB

 

8005T20062

TE FLAP

(CAN) DURING A ROUTINE INSPECTION, DISCOVERED LT AND RT WING RIBS AT STA 117.48 TO BE CONFLICTING WITH THE RIB AT SIMILAR LOCATION WHEN FLAPS ARE RETRACTED. AFTER INSPECTION, FOUND THAT THE SPOILER DOUBLER INSTALLED IN 1995 WAS THE WRONG DIMENSION ALLOWING WING RIB TO BE POSITIONED INCORRECTLY. ON FURTHER INVESTIGATION FOUND THE TEMPLATE NR 8005T AND THE INSTALLATION INSTRUCTIONS NR SP8000 SUPPLIED WITH THE STC SA4948NM TO BE CONTRADICTING EACH OTHER IN RESPECT TO THE NEW LOCATION OF THE WING RIB. IF ONE OF THE FLAPS BECAME INOPERATIVE DUE TO THE FACT THAT THE RIBS HOOKED ON EACH OTHER. (TC NR 20061117003)

CA070619006

CESSNA

CONT

 

WIRE

CUT  

6/18/2007

340A

TSIO520NB

 

 

MLG 

(CAN) LANDING GEAR WOULD NOT RETRACT AFTER TAKEOFF DUE TO A FAULTY WIRE TERMINAL CONNECTION BETWEEN THE (GEAR-UP LIMIT SWITCH) AND THE (GEAR MOTOR RELAY). (TC NR 20070619006)

2007FA0000695

CESSNA

CONT

 

SPAR

DAMAGED

7/18/2007

340A

TSIO520NB

 

 

MLG WW

WHILE INVESTIGATING A NOISE IN THE LANDING GEAR ACTUATOR GEARBOX, IT WAS DISCOVERED THA THE AN3-6A BOLTS ATTACHING THE ACTUATOR MOUNTING BRACKET, PN 50110133, TO THE FRONT CENTER SPAR WERE LOOSE. AN ATTEMPT TO TIGHTEN THE BOLTS REVEALED THAT THE NUTPLATES INSIDE THE SPAR WERE STRIPPED. THE NUTPLATES ARE NOT REFERENCED IN THE IPM AND APPEARS HAVE BEEN INSTALLED INSIDE THE SPAR DURING THE MFG PROCESS (INACCESSIBLE). AS A RESULT OF THE ABOVE CONDITION, WHEN THE GEAR IS RAISED OR LOWERED, THE BRACKET AND GEARBOX PULL AWAY FROM THE FWD CENTER SPAR AND TRANSMIT ALL THE FORCES TO THE AFT ATTACHMENT BULKHEAD, FLEXING THAT BULKHEAD BY MORE THAN .1250 INCH. NO INSTRUCTIONS FOR REPLACEMENT OF NUTPLATES IN MM. (K)

2007FA0000683

CESSNA

CONT

 

SKIN

CRACKED

7/12/2007

340CESSNA

TSIO520*

 

08220009

RT WING

CRACK IN THE TOP SKIN OF THE RT WING AT THE LANDING GEAR SIDE BRACE ATTACHMENT LOCATION, APPROX WS 63.45. THE SKIN IS 2024-T3 ALUMINUM, .032 THICK. THE CRACK IS ABOUT 4.5 INCHES LONG. (K)

CA070126011

CESSNA

 

 

TORQUE LINK

FAILED

1/18/2007

401  

 

 

50411148

RT MLG

(CAN) AIRCRAFT WAS DOING TOUCH AND GO`S ON THE 2ND LANDING PILOT REPORTED ABNORMAL LANDING AND NO GEAR UP INDICATION. GEAR CYCLED AND ONLY 2 OUT OF 3 INDICATOR LIGHTS ILUMINATED. RT MAIN, NO INDICATION. GEAR CYCLED AGAIN NO UP INDICATION AND NO RT GREEN DOWN INDICATION. AIRCRAFT COMPLETED FLY BY CONTROL TOWER WHEN PILOT WAS INFORMED OF HIS RT MAIN WHEEL AT A 45 DEGREE ANGLE. AIRCRAFT CARRIED OUT A FLY OVER OF MORGAN AIR`S FACILITY WHERE WITH BINOCULARS, I COULD SEE THE RT MAIN GEAR OVER CENTER DOWN AND LOCK WAS OVER CENTERED. PILOT CARRIED OUT SUCCESSFUL LANDING AND AIRCRAFT WAS REMOVED FROM RUNWAY WITHIN 10 MINUTES. (TC NR 20070126011)

CA070115015

CESSNA

CONT

 

MOUNT

LOOSE

1/12/2007

401  

TSIO520E

 

50110131

MLG GEARBOX

(CAN) DURING SCHEDULED LANDING GEAR ROUTINE INSPECTION, LANDING GEAR ACTUATOR GEARBOX MOUNTING BOLTS (3) FOUND MISSING AND REMAINING (1) BOLT FOUND SHEARED. EMERGENCY GEAR OPERATION ATTEMPTED TO RELOCATE GEAR. EMERGENCY OPERATION INHIBITED DUE TO IMPROPER GEARBOX ALIGNMENT. GEAR REPOSITIONED AND GEARBOX AND LANDING GEAR SYSTEM INSPECTED FOR CONDITION. NEW MOUNTING BOLTS INSTALLED AND GEAR SYSTEM NORMAL AND EMERGENCY TESTED SERVICEABLE. (TC NR 20070115015)

CA070125002

CESSNA

CONT

 

SCREW

BROKEN

1/24/2007

401B

TSIO520EB

 

08411131

RT MLG ADJ

(CAN) UPON LANDING RT MLG INADVETENTLY RETRACTED. AIRCRAFT VEERED OFF RUNWAY. AIRCRAFT INSPECTED AND CAUSE DEEMED FAILURE OF RT MLG ADJUSTING SCREW CAUSING SIDE BRACE ASSY TO UNLOCK. (TC NR 20070125002)

2007FA0000670

CESSNA

 

 

MASTER SWITCH

FAILED

3/9/2007

402C

 

 

IN31X100050CM358

 

LOST POWER TO THE AVIONICS BUSS. CARRIED OUT THE REQUIRED CHECKS AND TRIED REPEATEDLY TO RESTORE POWER TOT THE AVIONICS BUSS VIA THE EMERGENCY AVIONICS BUSS SWITCH, TO NO AVAIL. LANDED, CONTACTED MAINTENANCE, WHO CONFIRMED THE AVIONICS BUSS FAILURE. (K) INVESTIGATE AVIONICS BUSS SYS FAILURE AND FOUND AVIONICS MASTER SWITCH DEFECTIVE. MASTER SWITCH REMOVED AND REPLACED WITH NEW ITEM IAW MEB 05-1. FUNCTION CHECK OF MASTER AVIONICS SWITCH AND EMERGENCY AVIONICS BUSS SWITCH CARRIED OUT SATISFACTORY. (K)

CA070727002

CESSNA

CONT

 

CYLINDER HEAD

CRACKED

7/25/2007

402C

TSIO520VB

 

65354A10

ENGINE

(CAN) CYLINDER ASSY FOUND CRACKED DURING INSPECTION. LEAK COULD BE HEARD FROM CRACK DURING DIFF COMPRESSION TEST. CYLINDER REMOVED AND LARGE CRACK OBSERVED IN HEAD CASTING (INTERIOR VIEW). THE S/N OF CYLINDER REMOVED IS E41375-4 (TC NR 20070727002)

CA061123006

CESSNA

CONT

 

CAP  

CRACKED

11/20/2006

414  

TSIO520N

 

085150047

LT NACELLE

(CAN) CRACK NOTED AT LT NACELLE CANTED BULKHEAD CAP. CAP REPAIRED. (TC NR 20061123006)

2007FA0000749

CESSNA

CONT

 

EXHAUST PIPE

CRACKED

8/29/2007

414  

TSIO520NB

 

K99102991

ENGINE

DURING COMPLIANCE WITH AD 2000-01-16 THE TAIL PIPE ON THE RT ENGINE WAS FOUND WITH A 6 INCH CRACK. THE LAST INSPECTION WAS 40 HRS PRIOR.

2007FA0000648

CESSNA

 

 

DISPLAY

MALFUNCTIONED

7/20/2007

414A

 

 

GNS530W

GPS 

SETTING AN EVENT IN THE AUX PAGE FOR A FUTURE TIME CAUSES AUX EVENTS PAGE TO NO LONGER FUNCTION. SELECTING THIS PAGE CAUSES THE NAV6, GPS SATELLITE STATUS PAGE TO DISPLAY FOR 1 SECOND, THEN NAV2 PAGE(MAP) TO BE SELECTED. AS A SIDE EFFECT, THE FLIGHT TIMER IS RESET EVERY TIME THE AUX PAGE IS ATTEMPTED TO BE SELECTED. IT APPEARS THAT THE FIRMWARE BECOMES LOST, BUT RECOVERS.

CA070717005

CESSNA

PWA  

 

FILTER

CRACKED

6/19/2007

425  

PT6A112

 

021578201

FUEL PUMP

(CAN) DURING AN INSPECTION THE INLET FILTER WAS REMOVED. THE FILTER COVER (CAP) WAS FOUND CRACKED UNDER THE O-RING LOCATION ALL THE WAY AROUND. IT APPEARS TO HAVE BEEN OVER TORQUED. IT WAS NOT LEAKING AT THIS TIME. THE INLET FILTER ASSEMBLY WAS REPLACED. (TC NR 20070717005)

CA070510002

CESSNA

 

 

SKIN

DELAMINATED

1/17/2007

441  

 

 

 

STABILATOR

(CAN) FOUND DELAMINATION (OF 8 INCH X 16 INCH) ON TOP OF LT SIDE IB HORIZONTAL STABILIZATOR. DELAMINATION FOUND WHEN DOING PHASE 2 AND 3 INSPECTION. HORIZONTAL STABILIZATOR REPLACED, NO REPAIR IS ALLOWED ON HORIZONTAL STABILIZATOR IAW SRM. (TC NR 20070510002)

CA070607008

CESSNA

PWA  

 

UPLOCK ROLLER

WORN

6/7/2007

550  

JT15D4

 

MS2124010C40

MLG 

(CAN) CAMPAIGN NOTICE 851-32-40-040 AND 851-32-40-040R1 CARRIED OUT. ACTION WAS REQUIRED TO THE RT MAIN GEAR BEARING P/N MS21240-10C40. THE INSIDE BEARING MATERIAL WHEN INSPECTED WAS FOUND TO HAVE PIECES MISSING AND FURTHER INSPECTION REVEALED THE REMAINDER OF THE LINER WAS EASY TO REMOVE BY HAND. THERE WAS NO DAMAGE FOUND ON THE INNER SLEEVE OR ON THE BOLT. PRIOR TO DISASSEMBLY THE ROLLERS WERE INSPECTED IN SITU AND FOUND TO TURN WITH VERY LITTLE EFFORT REQUIRED. NEW BEARING WAS INSTALLED (TC NR 20070607008)

CA070607001

CESSNA

PWA  

 

BEARING

WORN

5/30/2007

550  

JT15D4

 

 

UPLOCK ROLLER

(CAN) AC WAS UNABLE TO LOWER THE RT MAIN LANDING GEAR. THE EMERGENCY EXTENSION PROCEDURE DID NOT INITIALLY RELEASE THE LANDING GEAR UPLOCK. SUBSEQUENT MANIPULATION OF THE SYSTEM RELEASED THE GEAR TO A DOWN AND LOCKED CONDITION AND THE AIRCRAFT MADE A SAFE LANDING. MAINTENANCE INVESTIGATION REVEALED (2) CONDITIONS WHICH CONTRIBUTED TO THIS SITUATION. IT WAS NOTED DURING INSPECTION OF THE SYSTEM THAT THE EMERGENCY EXTENSION CABLE WAS CONTACTING THE BRAKE ASSY IN SUCH A WAY THAT THE CABLE WAS BEING DEFLECTED APPROXIMATELY .2500 INCH AND COULD PREMATURELY PULL THE HOOK OFF THE ROLLER. THE CONCERN IS THAT THE CABLE MAY FRAY AND BREAK PREVENTING MANUAL EXTENSION OF THE GEAR. THIS WAS NOT A FACTOR IN THIS CASE. INVESTIGATION FOUND THAT THE RT MAIN GEAR UPLOCK REQUIRED 700 PSI TO RELEASE ON HYDRAULIC PRESSURE, AND A 70 POUND PULL TO RELEASE WITH THE EMERGENCY EXTENSION. INVESTIGATION FOUND THAT THE TEFLON LINER OF P/N MS21240-10C40 BEARING HAD DETERIORATED ON THE LOADED SIDE. REPLACING THE BEARING LOWERED THE HYDRAULIC PRESSURE REQUIRED TO RELEASE THE UP LOCK TO 400 PSI, AND REDUCED THE EMERGENCY EXTENSION PULL REQUIREMENT TO 40 LBS. MFG HAS BEEN INFORMED AND IS WORKING WITH THE OPERATOR AND STC HOLDER ON THESE ISSUES. (TC NR 20070607001)

CA070530001

CESSNA

PWA  

 

GYRO

DAMAGED

5/29/2007

550  

JT15D4

 

25863333

DIRECTIONAL

(CAN) DURING THE COMPLETION OF AN UNASSOCIATED SB IT WAS NOTICED THAT THE C-12 GYRO HAD FREED ITSELF OF ITS MOUNTING. UNTIL NOW NO COMPARATOR ANNUNCIATIONS OR COMPASS RELATED SNAGS HAD BEEN REPORTED OR DETECTED. (TC NR 20070530001)

CA070419001

CESSNA

PWA  

 

WIRE

CHAFED

4/18/2007

550  

JT15D4

 

 

NR 1 FEEDER

(CAN) DURING AN ATTEMPT TO RUN THE AIRCRAFT TO FUNCTION CHECK THE WINDSHIELD ANTI-ICE BLEED AIR (SNAG-NO BLEED AIR TO THE WINDSHIELD FOR ANTI-ICE UNTIL WINDSHIELD ANTI-ICE CB IS PULLED). WHEN THE BATTERY SWITCH WAS TURNED ON THE LT CB PANEL 35 AMP CIRCUIT BREAKER (LOCATED ON THE RT HAND CB PANEL) POPPED. IT WAS DISCOVERED THAT THE NR 1 FEEDER WIRE (P10A6) FOR THE LT BUSS, THE INSULATION HAD ABRADED THROUGH AND MADE CONTACT WITH A SCREW ON THE BACK OF THE DE-ICE PANEL ASSY. THIS WAS THE DIRECT CAUSE OF THE ABOVE MENTIONED 35AMP CIRCUIT BREAKER POPPING. WHEN THIS DE-ICE SIDE CONSOLE PANEL ASSY IS INSTALLED. (3) 6 GAUGE WIRES (ALL LT BUS FEED WIRES P10A6, P11A6 AND P12A6) ARE ROUTED IN BEHIND THIS PANEL. THE FIT IS VERY TIGHT (EXCEPTIONALLY POOR DESIGN AS THERE ARE NUMEROUS PROJECTIONS ON THE BACKSIDE OF THIS PANEL THAT COULD RESULT IN FURTHER ABRASION AND SUBSEQUENT SHORTING OF THESE BUS FEED WIRES. (TC NR 20070419001)

CA070425001

CESSNA

PWA  

 

ACTUATOR

MALFUNCTIONED

4/23/2007

550  

JT15D4

 

55275042

MLG 

(CAN) AIRCRAFT EXPERIENCED UNSAFE GEAR EXTENSION WHILE DOING CIRCUITS. GEAR SELECTION WAS MADE WHILE IN DOWNWIND TURN AND RT MAIN GEAR DOWN AND LOCKED LIGHT DID NOT ILLUMINATE, (GEAR UNLOCKED) AND (HYD PRESS ON) LIGHTS REMAINED ON. GEAR WAS RECYCLED IN LEVEL FLIGHT AND NORMAL INDICATION RESULTED. AIRCRAFT WAS FLOWN UNDER FERRY FLIGHT PERMIT WITH GEAR VERIFIED DOWN AND LOCKED. MAINTENANCE CONDUCTED SEVERAL GEAR SWINGS TO ENSURE PROPER OPERATION AND DOWNLOCK SWITCH CONTINUITY, WHICH REVEALED NO FAULTS. WHEN A LOWER THAN NORMAL HYDRAULIC PRESSURE WAS APPLIED AND GEAR DOWN SELECTION MADE, THE NOSE AND LT GEAR RELEASED BUT THE RT MAIN REMAINED IN THE UPLOCK. PRESSURE WAS THEN INCREASED TO NORMAL WITH NO EFFECT ON THE RT GEAR. TO FURTHER TEST THE SYSTEM WITH NORMAL HYDRAULIC SYSTEM PRESSURE, AN EXTERNAL DOWNWARD LOAD WAS APPLIED TO THE RT MAIN WHEEL DURING GEAR DOWN SELECTION, AGAIN THE NOSE AND LT MAIN RELEASED AND EXTENDED WHILE THE RT REMAINED UP AND LOCKED. THE GEAR EXTENDED UPON THE SELECTION OF THE EMERGENCY GEAR RELEASE. THE TEST WAS DUPLICATED ON THE LT GEAR AND IT RELEASED AS NORMAL. RT MAIN GEAR UPLOCK ACTUATOR P/N 5527504-2 WAS REPLACED WITH OVERHAULED UNIT AND SYSTEM FUNCTIONAL CHECKS CARRIED OUT SATISFACTORY. (TC NR 20070425001)

CA070409004

CESSNA

PWA  

 

WINDOW

DELAMINATED

4/2/2007

550  

JT15D4

 

551127517

COCKPIT

(CAN) PILOT`S STORM WINDOW DELAMINATED AT UPPER EDGE, RESULTING IN A CRACK FROM ATTACH HOLE RADIUS TO AFT EDGE. (TC NR 20070409004)

CA070221005

CESSNA

PWA  

 

BUCKLE

MALFUNCTIONED

2/6/2007

550  

JT15D4

 

 

SEATBELT

(CAN) COMPLIED WITH COMPANY CAMPAIGN NOTICE 010-25-10-011/SAIB NM-06-29. THE CREW SEATBELT ROTARY LATCH CAN BE CONTACTED WITH THE CONTROL YOKE LET DOWN HOLDER WITH THE SEAT FULL FORWARD AND THE YOKE FULL AFT. IT IS POSSIBLE TO UNLATCH THE SEATBELT BY ROTATING THE YOKE AND MAKING CONTACT WITH THE BUCKLE. THE FUNCTION TEST WAS CARRIED OUT IAW THE INSTRUCTIONS GIVEN IN SAIB NM-06-29. (TC NR 20070221005)

CA061109001

CESSNA

PWA  

 

TUBE

CRACKED

11/8/2006

550  

JT15D4

 

656530128

ELEVATOR

(CAN) DURING COMPLIENCE WITH CAMPAIGN NOTICE 851-27-20-035 (RUDDER AND ELEVATOR CABLE GUARDS) BOTH ELEVATOR CABLE GUARDS WERE FOUND TO BE UNSERVICEABLE. ALL (4) CLAMPS WERE DISTORTED AND CAUSED DISTORSION TO THE TUBES WHEN CLAMPED CAUSING CRACKS IN THE TUBES. BOTH ELEVATOR CABLE GUARD TUBES P/N 6565301-28 AND (4) CLAMPS P/N MS21919WD10 WERE REPLACE WITH NEW PARTS. THE RUDDER CABLE GUARDS WERE INSPECTED AND FOUND SERVICEABLE. (TC NR 20061109001)

CA070124002

CESSNA

PWA  

 

SOLENOID VALVE

FAILED

1/22/2007

550  

JT15D4

 

991240216

ANTI-ICE SYS

(CAN) STILL IN CRUISE CONFIG PILOTS DECIDED TO SELECT ANTI-ICE IN PREPARATION FOR DECENT TO AIRPORT. AT THIS TIME, A LT ANTI-ICE FAIL LIGHT ILLUMINATED. TROUBLESHOOTING LATER CONFIRMED THAT THE LT ENGINE ANTI-ICE VALVE HAD FAILED. THE VALVE IS POWERED 28VDC CLOSED UNTIL THE PILOT SELECTS ANTI-ICE ON, THEN POWER IS REMOVED AND THE VALVE IS OPENED BY ENGINE BLEED AIR PRESSURE. THE SYSTEM IS INTENDED TO BE A FAILSAFE SYSTEM, WHERE A NO POWER SITUATION WILL ALWAYS ALLOW BLEED AIR TO THE ENGINE INTAKE. THIS PARTICULAR VALVE FAILED TO PROVIDE THE FAILSAFE CONDITION. NO ENGINE BLEED AIR WAS AVAILABLE TO THE ENGINE INLET ALLOWING AN EXCESSIVE BUILD UP OF ICE. THIS CONDITION COULD HAVE LED TO ICE INGESTION CAUSING ENGINE DAMAGE OR AN IN-FLIGHT ENGINE SHUTDOWN. (TC NR 20070124002)

CA070123004

CESSNA

PWA  

 

FAN  

ODOR

1/21/2007

550  

JT15D4

 

99180021

WINDSHIELD

(CAN) ON APPROACH WHEN THE CREW SMELLED SOMETHING BURNING IN THE CABIN. THE CABIN FILLED UP WITH SMOKE AND THE CREW PUT ON THEIR MASKS AND DROPPED THE PASSENGERS MASKS. THEY LANDED WITHOUT DECLARING AN EMERGENCY. AN AME WAS SENT TO AND DETERMINED THAT THE DEFOG FAN WAS AT FAULT. THE FAN WAS DEFERRED AND WILL BE REPLACED ON ITS RETURN. (TC NR 20070123004)

CA070618001

CESSNA

PWA  

 

BEARING

WORN

6/17/2007

550  

JT15D4

 

MS2124010C40

MLG 

(CAN) THIS SDR IS BEING SUBMITTED TO SATISFY THE REQUIREMENT OF AIRCRAFT SERVICES DIRECTORATE CAMPAIGN NOTICE CN-1 851-32-40-040R1 THE INTERNAL TEFLON MATERIAL OF THE BEARING HAD DETERIORATED CAUSING THE BEARING TO BE DIFFICULT TO ROTATE. (TC NR 20070618001)

CA070215007

CESSNA

PWA  

 

BOLT

BROKEN

2/14/2007

560CESSNA

JT15D5

 

NAS464P4A10

NLG 

(CAN) AFTER GEAR WERE RETRACTED A VIBRATION IN THE NOSE OF THE AIRCRAFT WAS NOTICED. THE AIRCRAFT RETURNED TO BASE WITH NO INCIDENT. AN INSPECTION WAS CONDUCTED AND THE NOSE GEAR DOOR TORQUE TUBE ATTACH BOLT WAS FOUND BROKEN. THIS BOLT ATTACHES THE TORQUE TUBE TO THE WHEEL WELL STRUCTURE AND THE TORQUE TUBE ROTATES AROUND THIS BOLT. THE TORQUE TUBE WAS INSPECTED AND REINSTALLED. (TC NR 20070215007)

CWQR200708

CESSNA

PWA  

 

SUPPORT CHANNEL

CRACKED

7/31/2007

560CESSNA

JT15D5

 

556560914

INST PANEL

DURING MAINTENANCE FOUND THE RUDDER UPPER SUPPORT CHANNEL CRACKED WHERE IT ATTACHES TO THE INSTRUMENT PANEL. THIS AIRCRAFT HAD SL560-27-13 COMPLIED WITH 826.6 HOURS PRIOR TO FINDING THE CRACKED CHANNEL. THIS SL UPGRADED THE ATTACHING HARDWARE BUT DOES NOT CHANGE THE BRACKET. REPLACED BRACKET AND HARDWARE WITH NEW. AN SCR HAS BEEN SUBMITTED TO MFG UNDER NR 306488.

CWQR200709

CESSNA

PWA  

 

MOUNT

CRACKED

8/8/2007

560CESSNA

PW535A

 

65526022

NACELLE

DURING AN INSPECTION FOUND THE ENGINE NACELLE ATTACH FLANGE EARS CRACKED IN (2) LOCATIONS. SENT TO MFG FOR EVALUATION AND REPAIR. SUBMITTED SCR TO MFG UNDER NR 308174.

CWQR200710

CESSNA

PWA  

 

FORK

LOOSE

8/8/2007

560CESSNA

PW535A

 

55423002

NLG 

DURING A MAINTENANCE TAXI CHECK NOTICED SHIMMY FROM NOSE GEAR. UPON DISASSEMBLY FOUND FORK LOOSE ON NOSE GEAR PISTON, THIS SHOULD BE A PRESS FIT FROM THE FACTORY. SENT UNIT RELIABILITY GROUP FOR EVALUATION. A SCR HAS BEEN SUBMITTED TO MFG UNDER NR 308107.

CWQR200711

CESSNA

PWA  

 

INTAKE DUCT

CRACKED

8/13/2007

560CESSNA

PW535A

 

65526057

LT ENGINE

DURING A PHASE INSPECTION FOUND LT ENGINE INLET DUCT ASSY CRACKED. CRACKS WERE FOUND ON THE AFT PORTION OF THE INLET DUCT ASSY THROAT. THIS UNIT HAD TO BE RETURNED TO THE MFG FOR REPAIR. AN SCR WAS SUBMITTED TO MFG UNDER NR 308858.

CWQR200712

CESSNA

PWA  

 

INTAKE DUCT

CRACKED

8/13/2007

560CESSNA

PW535A

 

65526057

RT ENGINE

DURING A PHASE INSPECTION FOUND RT ENGINE INLET DUCT ASSY CRACKED. CRACKS WERE FOUND ON THE AFT PORTION OF THE INLET DUCT ASSY THROAT. THIS UNIT HAD TO BE RETURNED TO THE MFG FOR REPAIR. AN SCR WAS SUBMITTED TO MFG UNDER NR 308873.

CWQR200706

CESSNA

PWA  

 

PLATE

RUSTED

7/25/2007

560CESSNA

PW535A

 

663322513

RUDDER

DURING A PHASE 1-4 INSPECTION, NOTICED A RUST STAIN COMING FROM THE LOWER RUDDER BEARING PLATE ASSY (LOWEST HINGE POINT). UPON DISASSEMBLE, FOUND THE DRAIN HOLE FROM THE RUDDER TORQUE TUBE WAS DRAINING INTO THE LOWER BEARING PLATE ASSY. THIS IS DUE TO A NEW DESIGN OF THE PLATE ASSY, THE NEW ONE IS BEEFED UP AND HAS A BUILT UP AREA AROUND THE BEARING, THAT DIRECTS WATER TO THE BEARING, UNLIKE THE PREVIOUS DESIGN THAT WAS A FLAT PLATE AND ALLOWED WATER TO DRAIN AWAY FROM THE BEARING. SERVICE CONDITION REPORT HAS BEEN FILED WITH MFG UNDER NR 305034.

CWQR200704

CESSNA

PWA  

 

CLOSEOUT PANEL

CRACKED

7/16/2007

560XL

PW545A

 

66211511

LEFT WHEEL WELL

DURING A PHASE 5 INSPECTION, FOUND LT WHEEL WELL AFT SPAR CLOSE OUT PANEL CRACKED. (3) CRACKS WERE FOUND BEGINNING FROM THE LOWER SKIN ATTACH FLANGE AND GOES STRAIGHT UP THE PANEL. AN SDR HAS BEEN SUBMITTED TO AIRCRAFT UNDER NR 303303.

CWQR200705

CESSNA

PWA  

 

CLOSEOUT PANEL

CRACKED

7/16/2007

560XL

PW545A

 

66211511

LEFT WHEEL WELL

DURING A PHASE 5 INSPECTION, FOUND LT WHEEL WELL AFT SPAR CLOSE OUT PANEL CRACKED. (3) CRACKS WERE FOUND BEGINING FROM THE LOWER SKIN ATTACH FLANGE AND GOES STRAIGHT UP THE PANEL. AN SCR HAS BEEN SUBMITTED TO MFG AIRCRAFT UNDER NR 303303.

CWQR200707

CESSNA

PWA  

 

BALANCE WEIGHT

MISINSTALLED

8/21/2007

560XL

PW545A

 

66331508

RUDDER

DURING A PHASE 1-4 INSPECTION, FOUND THE RUDDER BALANCE WEIGHT WAS TRIMMED DOWN AND ATTACHED WITH ONLY (2) BOLTS.THE IPC SHOWS (4) BOLTS TO ATTACH THIS WEIGHT. CONTACTED MFG ENGINEERING, THEY STATED THE WEIGHT REQUIRES (4) BOLTS TO MEET THE 100 (G) STANDARD. APPEARS THE RUDDER BALANCE WEIGHT WAS TRIMMED DOWN AND INSTALLED AT THE FACTORY. REPLACED RUDDER BALANCE WEIGHT IAW SRM 51-60-03, RUDDER BALANCING. SUBMITTED SERVICE CONDITION REPORT TO MFG UNDER NR 310349.

CNQ2918C

CESSNA

 

 

THERMAL SWITCH

WARNING MESSAGE

7/26/2007

680CE

 

 

M1200180244

ANTI ICE SYSTEM

IN-FLIGHT AT FL 300, LT IB WING ANTI-ICE MSG ILLUMINATED, FOLLOWED BY ILLUMINATION OF THE LT WING ANTI-ICE COLD CAS MSG AND THE LT WING BLEED LEAK CAS MSG. FLIGHT CREW FOLLOWED CHECKLIST PROCEDURES; COULD NOT EXTINGUISH ANY AMBER CAS MSGS. FLIGHT CREW DIVERTED AIRCRAFT FOR MAINTENANCE. TECHNICIANS FOUND THE (2) ELECTRICAL LEAD WIRES BROKEN AT SL006 SWITCH, SOLDER CONNECTIONS. REPAIRED WIRES AND PERFORMED OPERATIONAL CHECKS; ALL OPERATIONAL CHECKS WERE SATISFACTORY. AIRCRAFT RETURNED TO SERVICE 07/19/07.

CA070705001

CESSNA

 

 

FADEC

MALFUNCTIONED

5/28/2007

680CE

 

 

 

 

(CAN) THE ENGINES FAILED TO RESPOND TO THROTTLE INPUT FOLLOWING TOUCHDOWN. PRELIMINARY INVESTIGATION REVEALED THE ISSUE RELATED TO THE FADEC`S RESPONSE TO ARMING THE THRUST REVERSERS ON APPROACH (NOT AN AFM PROCEDURE), COUPLED WITH A BOUNCE FOLLOWING INITIAL TOUCHDOWN. P&WC WILL INVESTIGATE AND ADVISE OF ROOT CAUSE ONCE ESTABLISHED. (TC# 20070705001)

CA070703004

CESSNA

CONT

 

CYLINDER

CRACKED

6/13/2007

A185E

IO520D

 

AEC631397

NR 2 

(CAN) CYLINDER CRACKED FROM FUEL INJECTOR TO SPARK PLUG HOLE, CRACK FOUND DURING 100 HR INSPECTION (TC NR 20070703004)

CA070716004

CESSNA

CONT

 

CYLINDER

CRACKED

5/11/2006

A185E

IO520D

 

AEC631397

NR 4 

(CAN) NR 4 CYLINDER FOUND CRACKED DURING INSPECTION (TC IN20070716004)

CA070731004

CESSNA

CONT

 

BELLCRANK

CRACKED

10/23/2006

A185E

IO520D

 

07123094

RUDDER

(CAN) BELLCRANK HAS CRACKS ADJACENT TO AN3 BOLT HOLES. (TC NR 20070731004)

CA070801004

CESSNA

CONT

 

CYLINDER

CRACKED

7/20/2007

A185E

IO520D

 

AEC65385

NR 6 

(CAN) DURING INSPECTION FOUND 6 CYLINDER CRACKED AT SPARK PLUG HOLE. (TC NR 20070801004)

CA070801005

CESSNA

CONT

 

CYLINDER

CRACKED

7/20/2007

A185E

IO520D

 

AEC65385

NR 5 

(CAN) DURING INSPECTION FOUND NR 5 CYLINDER CRACKED AT SPARK PLUG HOLE. (TC NR 20070801005)

CA070222003

CESSNA

CONT

 

BRACKET

CRACKED

2/22/2007

A185E

IO520D

 

07321014

HORIZONTAL STAB

(CAN) HORIZONTAL STABILIZERS REMOVED FOR REPAIR. AFT ATTACHMENT POINT REINFORCEMENT BRACKETS PN 0732101-4 REPLACED WITH NEW. ADJACENT RIVETS REPLACED. TAIL RE-ASSEMBLED. DUAL INSPECTED. (TC NR 20070222003)

CA070529005

CESSNA

CONT

 

SPAR

CRACKED

5/11/2007

A185F

IO520D

 

07310292

VERTICAL STAB

(CAN) DURING AN ANNUAL/100 HOUR INSPECTION FIN AFT SPAR WAS FOUND CRACKED. MFG SINGLE ENGINE CUSTOMER CARE SERVICE INFORMTION LETTER SE 80-85 ADDRESSES THIS PROBLEM. SERVICE KIT SK 185-25A INSTALLED THIS DATE. (TC NR 20070529005)

CA070711001

CESSNA

CONT

 

TUBE

CRACKED

6/5/2007

A185F

IO520D

 

 

RT NACELLE

(CAN) ONE TUBE CRACKED NEAR RT REAR ENGINE LOAD MOUNT. NEW MOUNT INSTALLED. (TC NR 20070711001)

2007FA0000643

CESSNA

 

 

WHEEL

MISREPAIRED

6/13/2007

R172K

 

 

G129 

NLG STRUT

DURING TAKEOFF FROM A GRASS STRIP AS THE AIRCRAFT APPROACHED 30 TO 40 KNOTS, BOTH NOSE WHEELS INSTALLED ON THE FLOATS FAILED, CAUSING THE AIRCRAFT TO FLIP ON TO ITS BACK. UPON EXAMINATION OF THE FLOAT NOSE WHEEL STRUTS THE FAILURE OCCURRED AT THE WELD JOINT OF BOTH LT AND RT WHEEL STRUTS. IT APPEARS THAT THE WELDS DID NOT HAVE ADEQUATE PENETRATION. INVESTIGATION OF MFG IN PROCESS. (K)

CA061109004

CESSNA

CONT

 

BRACKET

LOOSE

9/22/2006

T210L

TSIO520H

 

12430192

RT ELEVATOR

(CAN) BRACKET P/N 1243019-2 FOUND LOOSE AGAINST TORQUE TUBE P/N 1234650-2. LOOSE FASTENERS REMOVED AND REPLACED. (TC NR 20061109004)

2007FA0000641

CESSNA

CONT

 

LINE

MISMANUFACTURED

7/6/2007

T210N

TSIO520R

 

16864

FUEL SYSTEM

NEW FUEL INJECTOR LINE NR 5 CYL RAM PMA REPLACEMENT. INSTALLED ON ENGINES, WELD DEFECT ALLOWED DEVIPER END BAIL TO COME LOOSE FROM LINE. NOTED FUEL LEAN ON TOP OF ENGINE AT ANNUAL 100 HR INSP. (K)

2007FA0000713

CESSNA

CONT

 

CYLINDER

LEAKING

7/31/2007

T310Q

TSIO520NB

 

 

NR 6 

WHILE PERFORMING OTHER MAINTENANCE A FUEL STAIN WAS NOTICED BETWEEN THE SECOND AND THIRD COOLING FIN AFT OF THE FUEL INJECTOR ON THE NR 6 CYLINDER OF THE RT ENGINE. THIS CONDITION PROMPTED A CLOSER INSPECTION OF THE ENGINE RESULTING IN THE DISCOVERY OF SIMILAR STAINING ON THE NR 1 AND NR 5 CYLINDERS. EACH CYLINDER WAS INDIVIDUALLY PRESSURIZED AND LEAK CHECKED WITH A SOAPY WATER SOLUTION, NR 6 CYLINDER PRODUCED LARGE BUBBLES. THE CYLINDERS ARE ECI CASTING NR AEC65385 AND THERE WAS (A) STAMPED ON THE ROCKER BOX FLANGE WHICH REQUIRES NO FURTHER ACTION IAW AD 04-08-10. BY THE PILOTS STATEMENT THEY BELIEVE THERE IS APPROX. 1000 HOURS ON THESE CYLINDERS. RECOMMEND THAT A GOOD VISUAL INSPECTION BE PERFORMED AT 100 HOUR OR ANNUAL INSP, AND THAT A CURSORY INSPECTION FOR OBVIOUS FUEL STAINS BE PERFORMED WHEN THE COWL IS OPENED FOR MAINTENANCE. (K)

2007FA0000732

CESSNA

CONT

 

RELAY

FAILED

5/17/2007

T310R

TSIO520*

 

6041H274

BATTERY  

AIRCRAFT EMERGENCY LANDED WITH COMPLETE ELECTRICAL FAILURE, LG EMERGENCY EXTENDED AND LANDED SAFELY. FOUND BATTERY RELAY FAILURE. UNIT REMOVED 200 AMP FOUND TO BE INCORRECT (PN). SB MEB99-4 ADDRESS THIS PROBLEM, HAD NOT BEEN COMPLIED WITH, CORRECT RELAY 100 AMP PN 0850469-1 (6041H193) INSTALLED, OPS CHECK OK. (200 AMP RELAY HAD TO HAVE BEEN REPLACED PRIOR TO 1999 WHEN AC IPC REVERSED BATTERY AND STARTER RELAY PN COMPLIANCE WITH SB WOULD HAVE PREVENTED THIS PROBLEM. (K)

2007FA0000723

CESSNA

CONT

 

CHECK VALVE

WORN

8/23/2007

TU206C

TSIO520C

 

S23611

ENGINE OIL

AFTER FLIGHT A/C SITTING ON RAMP DEVELOPED LARGE OIL LEAK FROM TURBOCHARGER. FOUND OIL CHECK VALVE FLAPPER VALVE SEVERELY WORN.

CA070119010

CESSNA

CONT

 

SPAR

FAILED

1/16/2007

TU206G

TSIO520M

 

12220052

RT WING

(CAN) DURING REPLACEMENT OF LOWER OB SKIN, EDGE DISTANCE OF RIVETS THROUGH LOWER FLANGE LESS THAN MINIMUM ALLOWED IN 32 PLACES FROM STAT. 100.0 TO STAT. 154.00 REPLACEMENT OF PARTS REQUIRED TO REPAIR PROBLEM. (TC NR 20070119010)

CA070202010

CESSNA

CONT

CESSNA

HINGE BRACKET

WORN

2/2/2007

U206G

IO520F

 

12310231920

RUDDER

(CAN) DURING A 200 HR INSPECTION THE RUDDER WAS REMOVED FROM THE AIRCRAFT TO REPLACE THE RUDDER HINGE BEARINGS. INSPECTION OF THE RUDDER HINGE PIONT BRACKETS FOUND THE UPPER BRACKET P/N 1231023-19 OF THE LOWER HINGE POINT WORN COMPLETLY THROUGH BY THE BEARING, AND UPPER BRACKET P/N 1231023-20 HAD GROVES WORN INTO IT BY THE BEARING. THE BRACKETS WERE REPLACED WITH NEW PARTS AND THE RUDDER WAS REINSTALLED ON THE AIRCRAFT. (TC NR 20070202010)

CA070703005

CESSNA

CONT

 

MAGNETO

UNSERVICEABLE

6/8/2007

U206G

IO520F

 

662 

ENGINE

(CAN) SHEARED MOUNTING FLANGE HOUSING. (TC NR 20070703005)

CA070801003

CESSNA

CONT

 

PAN  

CRACKED

7/25/2007

U206G

IO520F

 

635616

ENGINE OIL

(CAN) OIL PAN FOUND CRACKED DURING INSPECTION. (TC NR 20070801003)

2007FA0000635

CIRRUS

CONT

 

ALTERNATOR

FAILED

6/29/2007

SR22

IO550N

 

646843

ENGINE

UPON RECEIPT OF CURRENT ALTERNATOR, NOTICED THAT SLIP-RING HOUSING WAS CLOCKED 180 DEGREES OUT OF ALIGNMENT OUT OF THE BOX. THIS PLANE HAS HAD SEVERAL REPAIRED ALTERNATORS INSTALLED ON IT. THE MOST RECENT ALTERNATOR HAD ONLY 131.1 HOURS BEFORE IT FAILED AND THE ONE PREVIOUS TO THAT ONE HAD 67.2 HOURS ON IT BEFORE IT FAILED. (K)

CA061123001

CNDAIR

PWA  

 

WIRE

CHAFED

11/23/2006

CL2151A10

CA3  

 

21551226808

DC POWER SYS

(CAN) DC OVERHEAD PANEL WIRES CHAFING ON AIRCRAFT STRUCTURE. (TC NR 20061123001)

CA070620002

CNDAIR

PWA  

HAMSTD

SOLENOID

INOPERATIVE

3/22/2007

CL2151A10

CA3  

4U1827

321524

PROP GOVERNOR

(CAN) DURING A TEST FLIGHT, THE NR 1 PROP WAS FEATHERED TO VERIFY CORRECT FUNCTION OF THE SYSTEM. THE FLIGHT CREW WAS UNABLE TO UNFEATHER THE PROPELLER AND RETURNED TO THE AIRPORT. MAINTENANCE CREWS FUNCTION TESTED THE SYSTEM ON THE GROUND AND THE SYSTEM FUNCTIONED CORRECTLY. THE PROP FEATHERING SOLENOID WAS SUSPECT AND WAS REPLACED. AIRCRAFT WAS RETURNED TO SERVICE. (TC NR 20070620002)

CA070801008

CNDAIR

PWA  

 

CYLINDER HEAD

CRACKED

7/20/2007

CL2151A10

CWASP

 

327626

ENGINE

(CAN) DURING A NORMAL WATER PICKUP FOR FIRE FIGHTING OPERATIONS, THERE WAS A NOTICEABLE LOSS OF MANIFOLD PRESSURE(MP) AND BMEP INDICATIONS. ON NR 1 POWER REDUCTION THERE WAS A SMALL BACKFIRE AND FURTHER LOSS OF MP AND BMEP. WATERLOAD WAS JETTISONED AND FLIGHTCREW REDUCED POWER TO CLIMB. THEY CLIMBED TO CRUISE ALTITUDE AND NOTICED A SMALL OIL LEAK AND SMOKE TRAIL. ALL OTHER INDICATIONS WERE NORMAL EXCEPT FOR A COLD CYLINDER HEAD TEMP. AFTER APPROX.: 45 WITH A SMOKE TRAIL AND OIL LEAK APPARENTLY GETTING WORSE, THE FLIGHTCREW SHUT DOWN AND SECURED THE RT ENGINE. AME FOUND CRACKED NR 2 CYCLINDER AND BROKEN PUSHROD AND HOUSING. CYLINDER WAS REPLACED, SCREEN CHECKED OK. ENGINE GROUND RUN AND FOUND SERVICEABLE. (TC NR 20070801008)

CA070801009

CNDAIR

PWA  

 

ELBOW

CRACKED

7/22/2007

CL2151A10

CWASP

 

41493

FIRE DETECTION

(CAN) DURING BOMBING OPERATIONS, FLIGHTCREW HAD AN INTERMITTENT RT, ZONE 1 FIRE INDICATION. THEY LEFT THE FIRE CIRCUIT, CLIMBED TO ALTITUDE, AND SECURED RT ENGINE IAW CHECKLIST. SHORTLY AFTERWARD (APPROX 5 MINUTES)THE LT GENERATOR FAILED. UPON ENTERING THE ZONE, ELECTRICAL POWER LOST TO RADIOS, MADE A LANDING WITHOUT INCIDENT. AMES FOUND CRACKED CERAMIC ELBOW ON FIRE DETECTION SYSTEM THE FOLLOWING DAY AFTER ANOTHER FALSE INDICATION. ELECTRICAL POWER CHARGING SYSTEM LOST WHEN LT ENGINE GENERATOR FAILED ON OPERATING ENGINE DURING SINGLE ENGINE OPERATIONS. GENERATOR REPLACED. SYSTEM CHECKED, FOUND SERVICEABLE. (TC NR 20070801009)

CA070716001

CNDAIR

PWA  

 

MOUNT

DAMAGED

7/14/2007

CL2151A10

R2800CA3

 

215340711

LANDING GEAR

(CAN) AFTER TAKEOFF, THE LANDING GEAR WAS RETRACTED AND THE RT/MAIN GEAR DID NOT INDICATE UP AND LOCKED. THE GEAR WAS SELECTED DOWN AND ALL (3) GEAR INDICTED DOWN AND LOCKED. MAINTENANCE HAS FOUND THE RT MAIN GEAR ACTUATOR MOUNTING DAMAGED. PARTS 215-34071-1,215-34071,215-34014-3,215-34014-2 ON ORDER. (TC NR 20070716001)

CA070711006

CNDAIR

 

 

FUEL CELL

LEAKING

7/11/2007

CL2156B11215

 

 

K215T6400212

 

(CAN) TESTED BEFORE INSTALLATION, THE CELL HAS BEEN FOUND LEAKING BY A PIN HOLE NEAR UPPER PROBE ADAPTOR AND REJECTED. (TC NR 20070711006)

CA070711004

CNDAIR

 

 

FUEL CELL

LEAKING

7/11/2007

CL2156B11215

 

 

K215T6400212

 

(CAN) TESTED BEFORE INSTALLATION, THE CELL HAS BEEN FOUND WITH LOOSE LOWER PROBED ADAPTOR AND LEAKING BY THE TOP CORNER REPAIR PATCH . THE CELL HAS BEEN REJECTED. (TC NR 20070711004)

CA070711003

CNDAIR

PWA  

 

FUEL CELL

LEAKING

7/11/2007

CL2156B11215

PW123

 

215640024

 

(CAN) FUEL CELL NR 7 RT, LEAKING BY THE LOWER INTERCONNECT CORNER. A/C HOURS: 1924 CYCLES: 1236 DROPS: 9808 (TC NR 20070711003)

CA070705006

CNDAIR

PWA  

 

SKIN

CRACKED

6/18/2007

CL2156B11215

PW123

 

215300174

BS 584.5

(CAN) A 3 INCH CRACK WAS DISCOVERED IN THE SKIN. CAUSE AT HIS TIME IS UNKKOWN AIND IS UNDER FURTHER INVESTIGATRION (TC NR 20070705006)

CA070705007

CNDAIR

PWA  

 

SKIN

CRACKED

6/18/2007

CL2156B11215

PW123

 

215300174

BS 584.5

(CAN) A (5) INCH CRACK WAS DISCOVERED IN THE SKIN AT APPROX F/S 584.50 AND W/L100. CAUSE AT THE TIME IS NOT KNOWN AND IS UNDER FURTHER INVESTIGATION. (TC NR 20070705007)

2007FA0000754

CNDAIR

GE  

 

MOTOR

UNSERVICEABLE

8/3/2007

CL6002B16

CF34*

 

604923063

HORIZ STAB TRIM

WHILE OPERATING HORIZ STAB TRIM ON CHANNEL NR 2 ONLY THE FOLLOWING OCCURS. PUSHING BUTTON ON CONTROL WHEELS TO NOSE UP, HORIZONTAL ACTUALLY WENT DOWN THEN DISCONNECTED. REPEATED ATTEMPTS, KEPT TRIMMING TO NOSE DOWN POSITION. COULD NOT GET HORIZONTAL TO TRIM NOSE UP ON JUST CHANNEL NR 2. ONCE CHANNEL NR 1 WAS ENGAGED HORIZONTAL STAB TRIM WORKED CORRECTLY. THIS PART WAS SENT TO THE MFG BY THE PREVIOUS OPERATOR FOR THIS EXACT PROBLEM. MFG REPLACED PARTS AND RETURNED IT TO SERVICE. PROBLEM REOCCURRED, UNIT REMOVED AND SENT BACK TO MFG. (K)

CA070713001

CNDAIR

GE  

 

PICCOLO TUBE

RUPTURED

7/10/2007

CL6002B19

CF343A1

 

14463108

 

(CAN) THE FLIGHT CREW RECEIVED AN ANTI-ICE DUCT WARNING MESSAGE DURING FLIGHT. THE APPLICABLE SYNOPTIC PAGE SHOWED THE RT WING LEADING EDGE BEING AT FAULT. WING ANTI-ICE SWITCH WAS SELECTED FROM NORMAL TO STAND-BY WITHOUT SUCCESS. DURING TROUBLESHOOTING, MAINTENANCE DISCOVERED THE RT WING OB ANTI-ICE DUCT (PICCOLO TUBE) REF IPC 30-11-00-10-240C END CAP MISSING. THE WELDED PICCOLO TUBE END CAP HAS RUPTURED FROM THE ASSY. THE ANTI-ICE DUCT ASSY WAS REPLACED IAW AMM 30-11-41 AND THE AIRCRAFT RELEASED INTO SERVICE. (TC NR 20070713001)

CA070724004

CNDAIR

GE  

 

WIRE

DAMAGED

7/21/2007

CL6002B19

CF343A1

 

CF61A22WHT

TE FLAPS

(CAN) IN CRUISE GEAR/FLAPS/BTMS INDICATIONS APPEARED WITH FLAP INDICATION SHOWING BOTH SIDES. FLAPLESS LANDING WAS SAFELY PERFORMED. MAINTENANCE FOUND WIRE CF61A22WHT AT CONNECTOR P2CF OF RT FLAP POSITION TRANSDUCER WITH DAMAGED INSULATION AND TOUCHING THE SHIELD OF THE HARNESS. WIRE REPAIRED (REO601R-20-12-001 AND REO601R-20-12-048); CONNECTOR P2CF (P/N D38999-26WB355N) AND HARNESS (P/N HET-A-02B) REPLACED. (TC NR 20070724004)

CA070729003

CNDAIR

GE  

 

STRUT

DAMAGED

7/28/2007

CL6002B19

CF343A1

 

601R319119

PAX DOOR

(CAN) ON ARRIVAL IT WAS DISCOVERED THAT THE PAX AIRSTAIR HAD BEEN DAMAGED WHEN CLOSED. MAINTENANCE FOUND A SMALL PUNCTURE IN THE MAIN CABIN DOOR INNER SKIN BESIDE UPPER STEP. MAINTENANCE DISCOVERED THE GAS STRUT ON THE MCD FAILED CAUSING THE SKIN PUCTURE BY CABLE ATTACHMENT ON THE DOOR BRACKET NOT RETRACTING. NDT C/O NO CRACKS FOUND, STRUT AND COUNTER BALANCE REPLACED AND REO 601R-52-11-1295 C/O WITH A RE-INSPECT OF THE SPEED TAPE EVERY 50 HRS. PRESENT A/C HOURS 25062:54 AND CYCLES 20668. (TC NR 20070729003)

CA070607011

CNDAIR

GE  

 

FCU  

MALFUNCTIONED

6/6/2007

CL6002B19

CF343A1

 

601R930507

TE FLAPS

(CAN) (FLAPS FAIL) MESSAGE DISPLAYED ON APPROACH. FLAPS FAILED WHEN SELECTING FROM FLAP 20 DEGREES TO FLAPS 30 DEGREES. FLAPS REMAINED AT 20 DEGREES AT A SPEED OF 170 KIAS. MAINTENANCE REPLACED FECU (FLAPS ELECTRONIC CONTROL UNIT) DUE TO UNABLE TO TEST AND THE LT BPSU (BRAKE POWER SENSOR UNIT) P/N 8550100-9, S/N 372. AIRFRAME HOURS: 24818:12 CYCLES: 20440. (TC NR 20070607011)

CA070131002

CNDAIR

GE  

 

FLAP SYSTEM

MALFUNCTIONED

1/31/2007

CL6002B19

CF343A1

 

 

TE FLAPS

(CAN) THE CREW REPORTED THAT ON APPROACH THAT THEY RECEIVED AN INITIAL FLAP HALFSPEED MESSAGE FOLLOWED BY A (FLAP FAIL) MESSAGE WHEN FLAPS SELECTED ON APPROACH. ZERO FLAP LANDING WAS COMPLETED. THE AIRCRAFT IS CURRENTLY WITH LINE MAINTENANCE TROUBELSHOOTING THE INCIDENT. (TC NR 20070131002)

CA070131005

CNDAIR

GE  

 

LANDING GEAR

INOPERATIVE

1/24/2007

CL6002B19

CF343B1

 

 

MAINS

(CAN) THE AIRCRAFT LANDED WITH ALL LANDING GEAR UP. BA FSR ON SITE. FSR REPORTED THAT THE ADG WAS DEPLOYED, AND FLAPS RETRACTED. AIRPORT AUTHORITIES ARE PRESENTLY IN THE PROCESS OF LIFTING THE A/C IAW THE AIRCRAFT RECOVERY MANUAL USING CRANES. AIRCRAFT CONDITION APPEARS TO BE GOOD. CONFIRMATION OF A WHEELS UP LANDING HAS BEEN RECEIVED. BA AIR SAFETY IS IN CONTACT WITH THE TSBC TO ESTABLISH WHAT ACTUALLY OCCURRED. IT IS NOT KNOWN IF THERE WERE ANY INJURIES. AN UPDATE WILL BE ISSUED SHORTLY. THE TSBC HAS CONTACTED THE CIAIC (SAFETY BOARD) OF SPAIN. THE BA RESPONSE WILL BE BASED ON THE NEXT UPDATE FROM BARCELONA. THE FOLLOWING COULD BE OBSERVED IN THE COCKPIT (VERY LIMITED TIME ALLOWED): LANDING GEAR CONTROL HANDLE WAS DOWN. ALTERNATE LDG RELEASE HANDLE WAS PUSHED IN. FLAP SELECTOR WAS AT 8 DEGREES. ADG MANUAL HANDLE WAS PUSHED IN. THE FOLLOWING COULD BE OBSERVED FROM THE OUTSIDE: ADG EXTENDED. NLG DOORS WERE CLOSED (THEY WERE OPENED LATER BY THE FSR). FLAPS POSITION AT 0 DEGREES. THE AIRCRAFT WAS THEN TOWED AWAY FROM THE RUNWAY AND IS NOW SITTING ON THE RAMP. THE DAMAGE IS EXTENSIVE AND RUNS FROM THE MLG BAY AREA TO THE AFT EQUIPMENT BAY. (TC NR 20070131005)

CA070618009

CNDAIR

GE  

 

O-RING

LEAKING

6/15/2007

CL6002B19

CF343B1

 

 

FUEL SYSTEM

(CAN) DURING FLIGHT, ENROUTE, THE CREW OBSERVED A RT FUEL LOW PRESS MESSAGE ON EICAS FOLLOWED BY FUEL IMBALANCE. AT 1000 LB FUEL DIFFERENTIAL BETWEEN TANKS, THE QRH PROCEDURE FOR FUEL IMBALANCE WAS INITIATED. AS A RESULT, THE RT ENGINE WAS SHUTDOWN. THE AIRCRAFT DIVERTED. AN EMERGENCY WAS DECLARED AND GROUND EMER EQUIP WAS ON STANDBY. THE AIRCRAFT LANDED WITHOUT FURTHER EVENT. MAINT FOUND A CLAMP FOR THE FUEL FEED LINE FROM THE RT COLLECTOR TANK WAS NOT PROPERLY ATTACHED. THE CLAMP HAD SHIFTED SUFFICIENT TO ALLOW A MISALIGNMENT OF THE FUEL LINES RESULTING IN THE ESCAPE OF FUEL AT THAT LOCATION. THE ROOT CAUSE FOR THIS IS NOT FULLY ESTABLISHED. MAINT REPLACED THE COUPLING O-RINGS AND RECONNECTED THE WIGGINS CLAMP TO CORRECT THE ANOMALY. IT SEEMS THAT SB: 601R-28-054 WAS RECENTLY COMPLIED WITH ON THIS AIRCRAFT. (TC NR 20070618009)

CA070618004

CNDAIR

GE  

 

CONNECTOR

MISINSTALLED

6/13/2007

CL6002B19

CF343B1

 

MS312183P

AUX TANK

(CAN) ON PATS RT AUXILARY TANK FOUND THE PRESSURE DIFFERENTIAL SWITCH, THE SOCKET OF THE SWITCH AND THE ELECTRICAL HARNESS CONNECTOR HAVING BOTH PINS, THE CONNECTOR SHOULD BE A FEMALE TYPE. THE DIFFERENTIAL SWITCH IS WORKING ONLY ON GROUND DURING FUELING. FOUND ALSO THAT THE SYSTEM IS WORKING BECAUSE THAT THE PINS ARE CONTACTING EACH OTHER. PATS THE STC HOLDER ADVISED AND A SB IS ALREADY OUT (TC NR 20070618004)

CA061124003

CNDAIR

GE  

 

FLAP SYSTEM

MALFUNCTIONED

11/23/2006

CL6002B19

CF343B1

 

 

TE FLAPS

(CAN) DURING APPROACH UPON INITIAL FLAP DOWN SELECTION, FLAP FAILED TO MOVE AND CREW RECEIVED (FLAP FAIL) MESSAGE ON EIACS. APPROACH CONTINUED AND NORMAL FLAPLESS LANDING CARRIED OUT. MAINTENANCE INSPECTION CARRIED OUT, NO EVIDENCE OF TWISTING, SKEWING OR DEFORMATIONS NOTED. FECU (FLAP ELECTRONIC CONTROL UNIT) CIRCUIT BREAKERS CYCLED IAW RE-SET PROCEDURE AND FLAPS FUNCTION CHECKED NORMAL OPERATIONS. (TC NR 20061124003)

CA070721001

CNDAIR

GE  

 

WIRE HARNESS

FAILED

7/18/2007

CL6002B19

CF343B1

 

 

MLG 

(CAN) THE A/C ARRIVED AND WAS TAXIING TO THE GATE WHEN IT WAS NOTED THAT NR 3 BTMS WAS ON THE RISE AND SUSPECTED DRAGGING BRAKES. THE FLIGHT CREW NOTICED THAT THE BRAKE TEMP MONITOR DROPPED TO ZERO. THE CAPTAIN GOT OUT OF THE A/C TO CHECK THE RT GEAR WHEN HE SAW THAT IT WAS ON FIRE, AT THIS TIME THE RAMP CREW EXTINGUISHED THE FIRE WITH A FIRE EXTINGUISHER. MAINTENANCE ON THE SCENE REPLACED NR3 MAIN WHEEL AND FOUND THAT THE DISCONNECT ON NR3 BRAKE LINE WAS LOOSE AND ONLY TOOK TWO TURNS TO REMOVE. IT IS SUSPECTED THAT THE QUICK DISCONNECT CONNECTOR MAY HAVE BACKED OFF CAUSING THE DRAGGING BRAKE CONDITION LEADING TO OVERHEAT AND FLUID LOSS CAUSING THE FIRE. NR 3 AND NR 4 BRAKES WERE REPLACED THE NIGHT BEFORE FOR GRABBING BRAKES, BUT THE A/C FLEW 5 LEGS BEFORE THE INCIDENT. ONCE THE A/C WAS TAKEN TO THE HANGER THE RT TRAILING ARM, AXLE, NR 3 AND NR 4 MAIN WHEELS, BRAKES, DUAL ANTI SKID CONTROL VALVE, LT ANTI SKID CONTROL VALVE, RT IB AND OB MAIN GEAR WIRE HARNESSES, TEMP SENSORS AND BRAKE LINE DISCONNECT FITTINGS WERE REPLACED. FUNCTION, LEAK CHECK AND TAXI TEST CARRIED OUT AND THE A/C WAS RETURNED TO SERVICE. (TC NR 20070721001)

CA070707001

CNDAIR

GE  

 

ACCUMULATOR

SEPARATED

7/6/2007

CL6002B19

CF343B1

 

0860163002

HYD SYSTEM

(CAN) DURING TAXI-OUT, HYD 1 LO PRESS MESSAGE CAME ON. THE CREW REPORTED LOUD BANG FROM AFT PART OF CABIN. CREW EXECUTED RELEVANT ABNORMAL CHECKLISTS AND RETURNED TO RAMP. AFTER VERIFICATION BY THE MTCE CREW, THEY FOUND OUT THAT THE NR 2 HYDRAULIC ACCUMULATOR SEPARATED. (TC NR 20070707001)

CA070627002

CNDAIR

GE  

 

CARBON SEAL

DAMAGED

6/24/2007

CL6002B19

CF343B1

CF343B1

4138T09P03

NR 2 ENGINE

(CAN) ON CLIMB OUT, CREW REPORTED NR 2 OIL PRESSURE WAS LOW AND FLUCTUATING BETWEEN 30-41 PSI. INTERMITTENTLY TRIGGERING THE LOW OIL WARNING. THE AIRCRAFT WAS DIVERTED AND LANDED NORMALLY. AT LOCATION, CONTRACT MAINTENANCE ADDED (4) QUARTS OF OIL AND A/C WAS CHECKED SERVICEABLE. THE A/C THEN RETURNED TO ORIGINATING BASE WHERE FURTHER TROUBLESHOOTING WAS TO BE CARRIED OUT. MAINTENANCE FOUND NR 2 ENGINE IDG CARBON SEAL DAMAGED. THE CARBON SEAL WAS REPLACED AND LEAK CHECKS AND RUNS CARRIED OUT AND CHECKED SERVICEABLE. A/C HRS.:17552:25, CYCLES:13370 (TC NR 20070627002)

CA070717002

CNDAIR

GE  

 

FMU  

UNSERVICEABLE

7/4/2007

CL6002C10

CF34*

 

4120T01P02

NR 1 ENGINE

(CAN) STARTING T/O, NR 1 ENGINE DID NOT RESPOND TO THROTTLE IN TOGA POSTION. ENGINE REMAINED AT IDLE. AFTER 10 SECONDS L ENGINE FLAMEOUT CAUTION MSG. T/O ABORTED AT 40 KNOTS. MDC (MAINTENANCE DIAGNOSTICS COMPUTER) INTERROGATED BY MAINTENANCE. FAULT CODE 353 BIT 29 SET, FMU CMD/POS DISAGREE (WF METERING VALVE ACTUAL POSITION DOES NOT MATCH EXPECTED POSITION BASED ON COMMAND). SUSPECT WF METERING VALVE TORQUE MOTOR. SUSPECT FAULTY COMPONENT: FMU 4120T01P02). FMU P/N4120T01P02 S/N12391265 REMOVED AND CHANGED IAW AMM 73-21-02-400-801-A01. ENGINE LEAK CHECKED AND FUNCTIONED SATISFIED. AIRCRAFT RETURNED TO SERVICE. (TC NR 20070717002)

CA070618010

CNDAIR

GE  

 

AXLE

SHEARED

6/13/2007

CL6002C10

CF34*

 

492033

MLG 

(CAN) WHILE LOADING, THE PASSENGER AT SLC THE FLIGHT CREW FELT A CERTAIN JOLT . INVESTIGATING THE SOURCE , THE CREW FOUND MLG NR 4 AXLE COMPLETELY SHEARED OFF. MLG NR 4 MLG AXLE COMPLETELY SHEARED OFF. (TC NR 20070618010)

CA070618008

CNDAIR

GE  

 

AXLE

BROKEN

6/17/2007

CL6002C10

CF34*

 

492009

LT MLG

(CAN) REPORTED A FRACTURED LT IB MLG AXLE (NR 2) ON A/C, LT SHOCK STRUT ASSY HAS P/N 49200-9 WITH SPP0049 WITH CURRENTLY. EFFECTED SUBASSY PISTON/AXLE HAS P/N 49263-1 WITH S/N BA0066 AND IS ORIGINALLY INSTALLED ON A/C SINCE DELIVERY. RT SHOCK STRUT ASSY HAS P/N 49200-10 WITH S/N SPP0097 AND SUBASSY PISTON AXLE ASSY WITH P/N 49263-1 AND S/N BA0111 AND BOTH HAVE TAC=7763 (ORIGINALLY INSTALLED SINCE DELIVERY). (TC NR 20070618008)

CA070720009

CNDAIR

GE  

 

WINDSHIELD

CRACKED

7/27/2006

CL6012A12

CF348E5A1

 

6003303025

COCKPIT

(CAN) LT WINDSHIELD OUTER PANE CRACKED IN FLIGHT WITH NO LOSS OF PRESSURIZATION. FLIGHT CONTINUED NORMALLY. NEW WINDSHIELD INSTALLED AND AIRCRAFT RETURNED TO SERVICE. (TC NR 20070720009)

CA070709001

CVAC

ALLSN

 

SHAFT

CRACKED

7/6/2007

30  

501D13H

 

24031404021

ROLL FORCE

(CAN) THE ROLL FORCE MODIFICATION WAS BEING INSTALLED IN THE AIRCRAFT IAW STC SA05-49. UPON TORQUING THE PILOT`S YOKE ASSEMBLY SHAFT IAW THE INSTRUCTIONS CONTAINED IN DOCUMENT K130-102-001-012, THE FLANGE ON THE SHAFT P/N 240-3140402-1 CRACKED. THE REMAINING AIRCRAFT IN THE FLEET WERE INSPECTED FOR SIGNS OF PLAY WITH NO DEFECTS NOTED. THE AIRCRAFT ARE ALSO BEING INSPECTED FOR EXCESSIVE BREAK AWAY TORQUE OF CONTROL YOKE SHAFT NUT. ANY ADDITIONAL FINDINGS WILL BE FORWARDED UPON COMPLETION OF THE INSPECTIONS. (TC NR 20070709001)

CA070724008

CVAC

ALLSN

 

RELAY

DAMAGED

7/24/2007

34030

501D13D

 

AH720

IGNITION POWER

(CAN) NR 1 ENGINE FAILED TO START DUE TO NO IGNITION. FOUND IGNITION RELAY P/N AH720 S/N CN-90127 FOUND CONNECTOR SEPARATED FROM BODY OF RELAY. RELAY REPLACED AND ENGINE GROUND RUN SERVICEABLE. (TC NR 20070724008)

CA070727009

CVAC

ALLSN

 

LEVER

DISTORTED

7/23/2007

440  

501D22

 

340315061627

LANDING GEAR

(CAN) UPON SELECTION OF (GEAR DOWN), THE LOCKING ARM OF THE LANDING GEAR SELECTOR HANDLE STUCK IN THE EXTENDED POSITION, PREVENTING ASSOCIATED FUNCTION OF DEPRESSING THE GEAR WARNING LIGHT SWITCH. THE RESULT WAS NO GEAR DOWN INDICATING LIGHTS ON THE ANNUNCIATOR PANEL. EMERGENCY PROCEDURES FOLLOWED AND AC LANDED WITHOUT INCIDENT. MAINTENANCE FOUND LANDING GEAR ACTUATING LEVER LOCKPIN JAMMED AND CONTROL HANDLE BEYOND THE 90 DEGREE POSITION. LEVER DISASSEMBLED, DAMAGE FOUND WAS A DISTORTED (CUPPED) INTERNAL ALUMINUM 960D10L WASHER. CUPPED WASHER REMOVED. NEW WASHER AND ONE EXTRA WASHER INSTALLED FOR SUPPORT DURING RE-RIG OF HANDLE WITHOUT COMPROMISING TRAVELS PER CONVAIR MAINTENANCE MANUAL LANDING GEAR MECHANICAL CONTROL SYSTEM 11.2 PG 102.LEVER ASSEMBLY SAFETIED, TESTED SERVICEABLE. LANDING GEAR SWING PERFORMED. (TC NR 20070727009)

2007001

CVAC

WRIGHT

 

SPAR CAP

CRACKED

7/17/2007

P4Y2TRANSAIR

R260035

 

 

CENTER WING

WHILE PERFORMING AD 2003-18-01, CRACKS WERE FOUND UNDER THE LT LOWER, FWD, SPAR CAP DOUBLER IN THE CAP, SPAR WEB AND THE DOUBLER ITSELF. CRACKS WERE ALSO FOUND IN THE WING SKIN CUTOUTS AT ALL 4 LOWER CENTER WING BELT FRAME CUT-OUTS. RT FWD LOWER SPAR CAP CRACKED IN (2) PLACES UNDER THE DOUBLER.

2007002

CVAC

 

 

SPAR CAP

CRACKED

7/17/2007

PB4Y2

 

 

 

CENTER WING

WHILE PERFORMING AD 2003-18-01, CRACKS WERE FOUND UNDER THE LT LOWER, FWD, SPAR CAP DOUBLER IN THE CAP, SPAR WEB AND THE DOUBLER ITSELF. CRACKS WERE ALSO FOUND IN THE WING SKIN CUTOUTS AT ALL 4 LOWER CENTER WING BELT FRAME CUT-OUTS. RT FWD LOWER SPAR CAP CRACKED IN ONE PLACE UNDER THE DOUBLER.

CA070802010

DHAV

PWA  

 

PLUNGER

SEIZED

8/1/2007

DHC2MK3

PT6A27

 

SAL2D864

CARGO DOOR

(CAN) DURING INSPECTION, FOWARD CARGO DOOR SWITCH PLUNGER WAS FOUND SEIZED. (TC NR 20070802010)

CA070727005

DHAV

PWA  

 

SEAL

FAILED

7/26/2007

DHC2MKI

R985AN14B

 

 

IMPELLER

(CAN) ENGINE REMOVED DUE TO EXCESSIVE OIL CONSUMPTION. UPON REMOVING NR 7 CYLINDER INTAKE TUBE, OIL WAS NOTED. THIS INDICATES POSSIBLE IMPELLER SEAL FAILURE. ENGINE WAS REMOVED FROM SERVICE. (TC NR 20070727005)

CA070731003

DHAV

PWA  

 

TORQUE TUBE

CRACKED

9/29/2006

DHC2MKI

R985AN14B

 

C2CF17778

RUDDER

(CAN) CRACK ON RUDDER TORQUE TUBE RT SIDE OB. (TC NR 20070731003)

CA070717019

DHAV

PWA  

 

PLUNGER

SEIZED

7/17/2007

DHC2MKI

R985AN14B

 

SAL2D864

DOOR SWITCH

(CAN) AT INSPECTION OBSERVED THE FRONT DOOR HANDLE IN OPEN POSITION BUT STILL ABLE TO START ENGINE. UPON INSPECTION, FOUND WITH DOOR OPEN MANUALLY OPERATING PLUNGER ON FORWARD DOOR LOCK OUT SWITCH ON LOWER DOOR SILL, FOUND SWITCH PLUNGER SEIZED IN CLOSED POSITION. THIS CAN ALLOW AIRCRAFT TO BE STARTED WITH FORWARD DOOR NOT LATCHED PROPERLY. RECTIFICATION IS TO REPLACE SEIZED SWITCH PLUNGER AND LUBRICATE SWITCHES ON A REGULAR BASIS. (TC NR 20070717019)

CA070711007

DHAV

PWA  

 

SELECTOR

STIFF

7/10/2007

DHC2MKI

R985AN14B

 

TC17300

FUEL 

(CAN) REMOVED CABLE DRUM FROM FUEL SELECTOR, LUBRICATED SELECTOR WITH YIELD AND REINSTALLED CABLE DRUM. (TC NR 20070711007)

CA070724002

DHAV

GARRTT

 

CABLE

FRAYED

7/11/2007

DHC3

TPE33110R

 

C3CF3487

ELEV TRIM

(CAN) DURING A 100/150 HOURS INSPECTION, THE ELEVATOR, LOWER TRIM CABLE (P/N: C3CF348-7) WAS FOUND FRAYED IN (2) LOCATIONS. THE FIRST LOCATION WAS IN THE PEDESTAL AREA WHERE THE TRIM CABLE ATTACHES TO THE ELEVATOR TRIM DRUM ASSEMBLY (P/N: C3CF222-3). IT APPEARS THAT THE CABLE WAS WEARING ON THE FWD AND REAR GUARDS P/N: C3CF310-3 AND C3CF309-3. THE SECOND AREA FOUND FRAYING WAS LOCATED IN THE UPPER CABIN AREA WHERE THE TRIM CABLE PASSES THROUGH FAIRLEAD BETWEEN FS 171.8 TO FS 194.8. CABLE REPLACED, AIRCRAFT RETURNED TO SERVICE. (TC NR 20070724002)

CA070717012

DHAV

PWA  

 

THRUST BEARING

BROKEN

6/11/2007

DHC3

R134059

 

288935

PROPELLER

(CAN) WHILE TAXIING FROM DOCK, THE AIRCRAFT ENGINE STARTED SHAKING AND THE PILOT SHUT THE ENGINE DOWN. AIRCRAFT TOWED BACK TO DOCK. AFTER RE-STARTING, STRANGE NOISES FROM NOSE CASE, AND PROPELLER LOOKED (OUT OF TRACK). PROPELLER REMOVED FROM COVER ON NOSE CASE REMOVED. BEARING SEPARATOR HAD STARTED TO BREAK UP. (TC NR 20070717012)

CA070717014

DHAV

PWA  

 

LINE

FAILED

7/11/2007

DHC6100

PT6*

 

061040M0240180

ENGINE OIL

(CAN) THE CREW OF FLOATPLANE EXPERIENCED A 10 LB LOSS OF TORQUE IN CRUISE ALONG WITH LOWERED OIL PRESSURE AND AN INCREASE IN OIL TEMP. THE PILOT CONTINUED THE FLIGHT TO A MAINTENANCE BASE USING REDUCED POWER ON THE AFFECTED ENGINE. AN UNEVENTFUL LANDING AND DOCKING WAS MADE. MAINTENANCE INVESTIGATION REVEALED THAT THE MAJORITY OF THE ENGINE OIL SUPPLY HAD BEEN EJECTED THROUGH THE ENGINE BREATHER SYSTEM. INSPECTION OF THE ENGINE OVERBOARD BREATHER LINE INTERNALLY REVEALED THAT IT HAD BROKEN DOWN AND PARTIALLY PLUGGED THE ACCESSORY CASE VENTING SYSTEM. THIS CAUSED THE ACCESSORY CASE TO PRESSURIZE AND THE ENGINE OIL TO VENT OVERBOARD. THE BREAKDOWN OF THE LINE RESULTED FROM THE LINE BEING POORLY ROUTED DURING INSTALLATION, CAUSING A (KINKING) ACTION AT ONE POINT, AS WELL AS THE LINE ITSELF BEING QUITE OLD. THE LINE WAS REPLACED AND THE AIRCRAFT WAS RETURNED TO SERVICE. (TC NR 20070717014)

CA070704002

DHAV

 

 

ROD  

MISMANUFACTURED

7/3/2007

DHC6300

 

 

C6CF14681

TE FLAPS

(CAN) DURING INSPECTION OF THE FLAP RODS IAW S/B 6/502 AND 6/388 IT WAS NOTICED THAT THE SWAGED END OF THE FLAP ROD WAS NOT COMPRESSED. UPON INSPECTION OF THE ROD IT WAS NOTED THAT THE COLLAR WAS NOT IN THE CORRECT POSITION AND HAD NOT BEEN COMPRESSED ENOUGH. THE SWAGED END MEASURES 0.9880OF AN INCH AND THE END IN QUESTION MEASURES 1.0055 OF AN INCH. THERE IS NORMALLY A BUMP IN THE SWAGED END, BUT THE END IN QUESTION DOES NOT HAVE ANY BUMP ON IT. (TC NR 20070704002)

CA070704016

DHAV

PWA  

 

GEARBOX

DISTRESSED

5/13/2007

DHC6300

PT6A27

 

 

ENGINE

(CAN) PRIOR TO START OF DESCENT, ENGINE OIL PRESSURE WAS SEEN TO FLUCTUATE. DURING THE DESCENT THE ENGINE FLAMED OUT. SUBSEQUENT INSPECTION REVEALED REDUCTION GEARBOX DISTRESS. MFG WILL INVESTIGATE THE EVENT AND ADVICE OF ROOT CAUSE ONCE ESTABLISHED. (TC NR 20070704016)

CA070802008

DHAV

PWA  

 

CONNECTOR

UNSERVICEABLE

7/27/2007

DHC6300

PT6A27

 

MS3126E1419S

WIRE HARNESS

(CAN) ON CLIMB OUT SHORTLY AFTER TAKEOFF, THE BETA WARNING LIGHTS (BOTH) CAME ON AND THE NR 2 PROPELLER STARTED TO FEATHER. THE PILOT PULLED THE BETA SYSTEM CIRCUIT BREAKER BUT THE LIGHTS DID NOT GO OFF, BUT THE PROPELLER STOPPED GOING TO FEATHER. THE PILOT LANDED AND CONTACTED MAINTENANCE. WHEN MAINTENANCE DID A GROUND RUN THE NR 2 PROPELLER WOULD NOT COME OUT OF FEATHER. TROUBLESHOOTING THE SYSTEM FOUND THAT THE CONNECTOR ON THE BETA SYSTEM CONTROL BOX WAS SHORTED OUT INTERNALLY, WHICH CAUSED FAULTS IN THE BETA CONTROL AND CAUTION LIGHT DIMMING CIRCUITS. THE BETA SYSTEM WAS CAUSED TO (THINK) THE NR 2 PROPELLER WAS GOING INTO BETA, WHEN ACTUALLY IT WAS NOT, AND THEREFORE STARTED TO FEATHER THE PROPELLER. THE CONNECTOR PLUG WAS REPLACED AND THE SYSTEM TESTED SERVICEABLE. (TC NR 20070802008)

CA070803002

DHAV

PWA  

 

TSCU

INOPERATIVE

8/2/2007

DHC6300

PW123

 

3014403

RIGHT

(CAN) AUTOFEATHER DID NOT ARM DURING THE TAKEOFF ROLL. TAKEOFF WAS ABORTED AND AN AUTOFEATHER TEST PERFORMED ON THE TAXIWAY WHICH ALSO DID NOT ARM THE AUTOFEATHER. RETURNED TO BLOCK WHERE MAINTENANCE PERFORMED TROUBLESHOOTING AND REPLACED THE RT TSCU. (TC NR 20070803002)

CA070710004

DHAV

PWA  

 

GUIDE VANE

FAILED

4/26/2007

DHC7102

PT6A50

 

3034051

ENGINE

(CAN) DURING FLIGHT, THE TURBINE TEMPERATURE ROSE SUDDENLY FROM 738 TO 785 DEGREES CELSIUS. A BORESCOPE INSPECTION REVEALED DAMAGE TO THE CT GUIDE VANE. THE ENGINE WAS REPLACED AND THE AIRCRAFT RETURNED TO SERVICE. THE HOT SECTION WAS REMOVED FROM THE ENGINE AND FURTHER INSPECTED. ONE OF THE CT GUIDE VANE’S AIRFOIL-COOLING DUCT SURFACE HAD BEEN PREVIOUSLY REPAIRED. THE VANE CRACKED/FAILED AROUND THE WELDS ALLOWING THE COOLING DUCT TO OPEN UP AND BREAK AWAY. WITHOUT THE PROPER COOLING THE VANE BURNED THROUGH. THE HOLE IN THE VANE CHANGED THE AIRFLOW ALLOWING DIRECT FLOW TO THE CT BLADES IN TURN CAUSING THEM TO OVERHEAT. GUIDE VANE CSO 48. THIS IS THE SECOND FAILURE OF THIS NATURE AS THE OTHER FAILURE OCCURRED ON A VANE WITH CSN 689 AND WAS FOUND DURING ROUTINE INSPECTION. THE BACKSIDE OF THE AIRFOIL-COOLING DUCT HAD BURNED THROUGH IN THE REPAIRED AREA. THE VANE WAS REPLACED. BOTH VANES HAD SIMILAR REPAIRS IN THE FAILED AREA. THE VANES WERE RETURNED TO THE OVERHAUL FACILITY FOR FURTHER INVESTIGATION. THE OVERHAUL FACILITY SUSPECTS THAT THE VANES FAILED DUE TO OVERHEATING. THERE WERE NO INDICATIONS OF OVERHEATING PRIOR TO THE OCCURRENCES ON EITHER AIRCRAFT. (TC NR 20070710004)

CA070718001

DHAV

PWA  

 

REGULATOR

FLUCTUATES

7/8/2007

DHC8101

PW120A

 

310573501A

ENGINE OIL

(CAN) DURING FLIGHT, THE OIL PRESS INDICATOR NR 1 ENGINE, DROPPED TO 50 PSI. QRH DRILL COMPLETED, UNSCHEDULED LANDING COMPLETED. OIL PRESSURE REGULATOR ASSEMBLY REPLACED IAW AMM 71-01-50, SYSTEM TESTED SERVICEABLE AND AIRCRAFT RETURNED TO SERVICE. (TC NR 20070718001)

CA070719009

DHAV

PWA  

 

FLEX DRIVE

SEIZED

6/28/2007

DHC8102

PW120A

 

745583A

TE FLAPS

(CAN) FLIGHT CREW REPORTED (FLAP DRIVE) CAUTION LIGHT ILLUMINATED FROM 2-3 SECONDS WHEN FLAPS SELECTED. MAINTENANCE INSPECTION FOUND FLAP SECONDARY DRIVE, IN WING CENTER SECTION, CORE HAD UNWOUND AND SEIZED CAUSING THE CASING TO ROTATE AND DAMAGED SUPPORT BRACKET AND TORQUE SENSOR. FLAP CORE APPEARED TO LACK LUBRICATION AND RUST WAS EVIDENT. FLAP SECONDARY FLEX SHAFT REPLACED. ALL OTHER FLAP SECONDARY DRIVES LUBRICATED. BRACKET AND TORQUE SENSOR DAMAGE REPAIRED. AIRCRAFT RETURNED TO SERVICE. FLAP SECONDARY DRIVE IS CLASSIFIED AS AN EXPENDABLE PART AND TIME ON PART NOT TRACKED. (TC NR 20070719009)

CA070704003

DHAV

PWA  

 

BOLT

LOOSE

7/4/2007

DHC8102

PW120A

 

85210276101

HANDRAIL SUPPORT

(CAN) CREW REPORTED THAT MAIN CABIN DOOR WOULD STOP OPENING SOMETIMES. FLIGHT ATTENDANT HAD TO PUSH THE HANDRAIL TO GET THE DOOR FULLY OPEN. LINE MAINTENANCE FOUND REAR HANDRAIL SUPPORT STRUT BOLT (REF IPC 52-10-00-35-50) UNSCREWED AND CONTACTING WITH HANDRAIL LOWER NEWEL STRUT (REF IPC 52-10-00-40-90). THE BOLT HAS NO LOCKING FEATURE. THE BOLT WAS TIGHTENED, SYSTEM CHECKED SERVICEABLE AND THE AIRCRAFT RELEASED INTO SERVICE (TC NR 20070704003)

CA070802009

DHAV

PWA  

 

TSCU

MALFUNCTIONED

7/2/2007

DHC8201

PW123D

 

30005000056

NR 2 

(CAN) AUTOFEATHER ARM LIGHT FAILED TO ILLUMINATE DURING TAKEOFF ROLL (AUTO FEATHER SYSTEM INOP). REPLACED THE NR 2 TSCU IAW P/W MM 72-01-10, PAGE 420-424, PARAGRAPH 7. GROUND RUNS COMPLIED WITH. OPERATIONAL CHECK GOOD. AIRCRAFT RETURNED TO SERVICE. (TC NR 20070802009)

CA070727001

DHAV

PWA  

 

FITTING

BROKEN

7/27/2007

DHC8202

PW123D

 

AN81510

FUEL MANIFOLD

(CAN) ENGINE DRIVEN PUMP NR 1, INLET PRESSURE MANIFOLD FITTING AN 815-10 BROKEN IN FLIGHT. FITTING HAS BEEN REPLACED AND A/C RETURNED TO SERVICE. (TC NR 20070727001)

CA070718003

DHAV

PWA  

 

COMPUTER

FAILED

7/17/2007

DHC8301

PW123

 

906100004

STALL WARNING

(CAN) DURING CRUISE, THE NR 2 STALL SYSTEM FAIL AND PUSHER SYSTEM FAIL CAUTION LIGHTS ILLUMINATED. QRH CHECKLIST WAS PERFORMED. UNSCHEDULED LANDING COMPLETED. DUAL STALL WARNING COMPUTER DETERMINED TO BE THE CAUSE OF THE REPORTED DEFECT. DUAL STALL WARNING COMPUTER REPLACED IAW AIRCRAFT MM CHAPTER 27-33-00 AND SYSTEM TESTED SERVICEABLE. AIRCRAFT RETURNED TO SERVICE. (TC NR 20070718003)

CA070709002

DHAV

PWA  

 

GENERATOR

INOPERATIVE

7/7/2007

DHC8301

PW123

 

HCAIN022

NR 2 

(CAN) AT THE END OF EXTENSIVE POST BLOCK CHECK GROUND RUNS; THE NR 2 ENG GEN FELL OFF LINE AND NR 1 TRU AND AC BUS FELL OFF LINE; TRIED TO POWER BACK AND RESET IT WAS NOTICED THAT THE AC GEN CAUTION LIGHT WAS NOT SHOWING. SO THE AIRCRAFT WAS SHUTDOWN AND AFTER SOME INVESTIGATION IT WAS FOUND THAT THE AC GEN CONTACTOR HC-AIN-022 HAD FAILED INTERNALLY MELTING THE RELAY AND ASSOCIATED WIRING. (TC NR 20070709002)

CA070717004

DHAV

PWA  

 

ROD  

FAILED

6/28/2007

DHC8311

PW123

 

85210240055

PAX DOOR

(CAN) PASSENGER DOOR AFT SUPPORT STRUT BROKE MAKING IT DIFFICULT TO OPEN THE MAIN CABIN DOOR. EXPLANATION CODES: 7(A) SPECIAL OPS- AIRCRAFT HAD ALREADY LANDED AND PASSENGERS WERE ABOUT TO DISEMBARK. 7(B) DOOR WAS DIFFICULT TO OPEN. 7(C) DOOR WAS OPENED BY (2) CREW MEMBERS. (TC NR 20070717004)

2007FA0000721

DIAMON

 

 

CABLE

BROKEN

8/22/2007

DA40

 

 

 

ALTERNATOR

ALTERNATOR CABLE INSTALLED AT THE FACTORY WAS TOO SHORT. CABLE CONNECTS TO ALTERNATOR CIRCUIT BREAKER.

2007FA0000711

DIAMON

CONT

 

RESISTOR

DAMAGED

7/10/2007

DA40

IO360*

 

 

ALTERNATOR

MFG FABRICATED AN IN-LINE RESISTOR FROM THE ALTERNATOR TO THE VOLTAGE REGULATOR. THE RESISTOR WAS LOCATED APPROXIMATELY 2 INCHES FROM AUX TERMINAL ON ALTERNATOR. IT WAS STRENGTHENED WITH MULTIPLE LAYERS OF HEAT-SHRINK AND TERMINAL WAS CRIMPED ON THE SOLID WIRE LEAD OF THE RESISTOR. THE AIRCRAFT HAD INTERMITTENT ALT FAIL WARNING BUT HAD NORMAL, POSITIVE SYSTEM CHARGING. UPON DISCOVERY OF THE FAULT, THE RESISTOR LEAD WAS HELD IN THE TERMINAL CRIMP BY THE HEAT SHRINK BUT THE SOLID WIRE WAS BROKEN, MOMENTARILY MAKING CONTACT CAUSING THE FAULT. THE PROBLEM WAS CORRECTED BY SOLDERING A SMALL SECTION OF WIRE TO THE RESISTOR AND INSTALLING A NEW TERMINAL TO WIRE. MFG CUSTOMER SUPPORT WAS CONTACTED AND THEY WERE AWARE OF THE PROBLEM. THEY NOW FABRICATE THE RESISTOR ON A CIRCUIT BOARD MATERIAL AND INSTALL LENGTH OF WIRE FROM RESISTOR TO ALTERNATOR. (K)

CA070529004

DORNER

 

 

BOOT

LOOSE

5/7/2007

DO328100

 

 

29S7D524007

DE-ICE SYSTEM

(CAN) PILOTS REPORTED LT HORIZONTAL STAB DE-ICE BOOT APPEARS LOOSE. MAINTENANCE INSPECTED THE BOOT AND FOUND THE DE-ICER BOOT HAD COME LOOSE FROM THE AIRCRAFT AT THE AFT EDGES. THE ADHESIVE (3M 1300L) DID NOT SECURE THE DEICER BOOT TO STAB. THE DEICER BOOT WAS RECENTLY REPLACED UNDER WORK ORDER 15249. TIME ON PART 54.6 HOURS AND 73 LANDINGS. DEICER BOOT REPLACED AND AIRCRAFT RETURNED TO SERVICE. (TC NR 20070529004)

CA070725004

DORNER

PWA  

 

BOOT

LOOSE

5/4/2007

DO328100

PW119C

 

29S7D524007

HORIZONTAL STAB

(CAN) PILOTS REPORTED LT HORIZONTAL STAB. DE-ICER BOOT APPEARS LOOSE. MAINTENANCE INSPECTED THE DE-ICER BOOT AND FOUND THE BOOT HAD COME LOOSE FROM THE AIRCRAFT AT THE AFT EDGES. THE ADHESIVE (3M 1300L) DID NOT SECURE THE DE-ICER BOOT TO THE STAB. THE BOOT WAS RECENTLY REPLACED BY AC SERVICES, UNDER WO 15249. TIME ON PART WAS 54.6 HOURS AND 73 LANDINGS THE DE-ICER BOOT WAS REPLACED AND THE AIRCRAFT RETURNED TO SERVICE. (TC 20070725004)

CA070502014

DORNER

PWA  

 

FEEDER CABLE

CHAFED

4/24/2007

DO328300

PW306B

 

 

ALTERNATOR

(CAN) DURING TROUBLESHOOTING OF INTERMITTENT AC ALTERNATOR FOUND FEEDER WIRE CHAFED AND ARCED TO COWL STRUCTURE. STRUCTURE AFFECTED IS RETAINER FOR COWL SUPPORT ARM. (TC NR 20070502014)

CA070625004

DOUG

PWA  

 

SUPERCHARGER

FAILED

6/24/2007

DC6B

BWASP

 

 

ENGINE

(CAN) AT TOP OF CLIMB ENGINE POWER DECREASED TO 20 INCH MANIFOLD PRESSURE AND 80 BMEP. ENGINE WAS SHUTDOWN AND AIRCRAFT RETURNED TO AIRPORT. SUSPECT ENGINE SUPERCHARGER BLOWER FAILED. (TC NR 20070625004)

2007FA0000708

DOUG

 

 

LOCK

MALFUNCTIONED

8/13/2007

DC8*

 

 

 

COCKPIT DOOR

NOTIFY BY AIR SECURITY REPORT THAT OUR COCKPIT LKD SYSTEM INFORMS US ONLY IF IT'S ARMED OR NOT, BUT NOT IF THE DOOR IS CORRECTLY CLOSED AND LOCKED. DURING ONE OF THE LAST FLT'S MY COCKPIT DOOR HAS BEEN OPENED BY THE PURSER WITHOUT MY PERMISSION. THE DOOR SEEMED CLOSED BUT IT WASN’T AND HE COULD OPEN IT EASILY. IT IS UNSAFE FOR US ON BOARD AND FOR ALL PEOPLE THAT WE FLY OVER. EUROPEAN AVIATION SAFETY AGENCY POSTFACH 10 12 53 D-50452 KOELN, GERMANY I'M MD80 CPT OF ALITALIA , I NOTIFY BY AIR SECURITY REPORT THAT OUR COCKPIT LKD SYSTEM INFORMS US ONLY IF IT'S ARMED OR NOT, BUT NOT IF THE DOOR IS CORRECTLY CLOSED AND LOCKED. DURING ONE OF THE LAST FLT'S MY COCKPIT DOOR HAS BEEN OPENED BY THE PURSER WITHOUT MY PERMISSION. THE DOOR SEEMED CLOSED BUT IT WASN’T AND HE COULD OPEN IT EASILY. IT IS UNSAFE FOR US ON BOARD AND FOR ALL PEOPLE THAT WE FLY OVER. I GIVE YOU MY NAME BUT IT'S BETTER FOR ME YOU DON’T SHOW MY NAME TO ANYBODY. TKS CPT VALERIO POCEK V.POCEK@LIBERO.IT +39 3402772347

CO1Y200700001

DOUG

 

 

LONGERON

CRACKED

8/18/2007

MD11

 

 

A6A71211

ZONE 100

CAC COMPARTMENT AT STA 6-100 ON LONGHERON NR 37LT SIDE FOUND CRACK 1 INCH.

CO1Y200700002

DOUG

 

 

DOUBLER

CORRODED

8/18/2007

MD11

 

 

AEA75732

BS 1321-1341

MAIN CABIN FROM STA 1321 TO STA 1341 FROM L NR 13 TO L NR 14 RT SIDE ON DOUBLER FOUND CORROSION.

WGEA200700001

ECLIPS

 

 

ACTUATOR

MALFUNCTIONED

8/3/2007

ECLIPSEEA500

 

 

EM41165

T/E FLAPS

FLAP FAIL CAS MESSAGE IN FLIGHT. REMOVED AND REPLACED LT AND RT INBOARD FLAP ACTUATORS PER EA 500 AM CH 27-51-11. RIGGED FLAP`S AND COMPLIED WITH SATISFACTORY FUNCTIONAL/OPERATIONAL CHECKS.

2007FA0000680

ECLIPS

 

 

SENSOR

FAULTY

7/29/2007

ECLIPSEEA500

PW610FA

 

35C155103

OIL TEMP

RT ENG HIGH OIL TEMPERATURE CAS MESSAGE UPON LANDING. EXCEEDANCE (OIL TEMP) AFTER LANDING-ENGINE SHUTDOWN DURING TAXI. FOUND FAULTY MOT/MOP SENSOR REPLACED WITH NEW UNIT AND OPERATIONALLY CHECKED SATISFACTORY IAW EMM 79-30-04.

EY2R0097613

EMB  

 

 

BEARING

CORRODED

7/18/2007

EMB120

 

 

7826761

BLADE

PROPELLER BLADE BEARING CORRODED.

CA070706003

EMB  

GE  

 

BRAKE ASSY

OVERHEATED

7/3/2007

ERJ190100IGW

CF34*

 

 

MLG 

(CAN) HOT BRAKE INDICATION ON TAXI IN OF 460 CELSIUS. BRAKE OVERTEMP INSPECTION CARRIED OUT WITH NO FAULTS. CMC MESSAGE BRAKE TEMP SENSOR OVERHEAT. IAW FIM, REPLACE TEMP SENSOR. PLACED ON MEL DUE NO STOCK. FOLLOWING DAY, RT IB/OB BRAKE TEMPERATURES CREPT UP TO 110/ 195 CELSIUS. THERE IS A HISTORY OF HYDRAULIC CONTROL PROBLEMS, POSSIBLE CAUSE IN THIS CASE MAY BE THE BRAKE CONTROL VALVE. (TC NR 20070706003)

CA070528013

EMB  

GE  

 

MODULE

MALFUNCTIONED

5/22/2007

ERJ190100IGW

CF3410E6

 

1855A000003

NLG STEERING

(CAN) STEERING FAIL MESSAGE ON FINAL APPROACH, FLIGHT DID 2 MISSED APPROACHES FOR GEAR RECYCLING, LANDED ON THIRD CYCLING OF GEAR. FLIGHT HISTORY DATA BASE DOWNLOADED, MFG REP FOUND STEERING CONTROL MODULE AT FAULT. ACFT THR 3643, TCY 1663 (TC NR 20070528013)

CA070227006

GROB

LYC  

 

HANDLE

FAILED

2/22/2007

G120A

AEIO540D4D5

 

GH115TAREVE

LANDING GEAR

(CAN) LANDING GEAR HANDLE FAILED TO GIVE GEAR POSITION LIGHT AND IN-TRANSIT LIGHT INDICATIONS DURING A TRAINING MISSION. THE PILOT ELECTED TO FLY BY THE TOWER FOR ALL GEAR IN EXTENDED POSITION CONFIRMATION BEFORE AN UNEVENTFUL LANDING. AFTER SHUTDOWN, THE LANDING GEAR POSITION LIGHTS BEGAN TO FUNCTION NORMALLY. MAINTENANCE PERSONNEL PLACED THE AIRCRAFT ON JACK AND TRIED UNSUCCESSFULLY TO DUPLICATE THE SNAG. THE WIRING AND TERMINALS WERE INSPECTED FOR FAULTS. NUMEROUS GEAR SWINGS WERE PERFORMED. THE AIRCRAFT WAS RELEASED SERVICEABLE. HISTORICALLY, THE LANDING GEAR HANDLE UNIT POSITION LIGHTS HAVE FAILED ON GROUND CHECKS AND THE UNITS (A FLEET OF 9 NEW (2006) AIRCRAFT) WERE SYSTEMATICALLY UPGRADED TO REVISION (E) STATUS. (TC NR 20070227006)

CA070115012

GULSTM

GARRTT

 

ANGLE

CRACKED

12/14/2006

690D

TPE3315

 

320035501

BULKHEAD

(CAN) FLIGHT CREW REPORTED LOWER THAN NORMAL CABIN DIFFERENTIAL PRESSURE. A GROUND PRESSURIZATION CHECK WAS CARRIED OUT AND FOUND LEAK IN AREA OF AFT PRESSURE BULKHEAD LOWER SECTION. FURTHER INSPECTION REVEALED A CRACK IN THE BEND RADIUS OF ANGLE P/N 320035-501. P/N M690003-4 FIGURE 2-56D ITEM II. NEW ANGLE INSTALLED AND SEALED. GROUND PRESSURIZATION CHECK CARRIED OUT OKAY. (TC NR 20070115012)

CA070115013

GULSTM

GARRTT

 

FILLET

CRACKED

12/19/2006

690D

TPE3315

 

1101918

RT WING

(CAN) DURING INSPECTION OF THE AIRCRAFT A CRACK WAS SUSPECTED IN THE RT UPPER FILLET WING TO FUSELAGE. NON DESTRUCTIVE TESTING CONFIRMED (2) CRACKS, 25 MM AND 18 MM LENGTH. LT UPPER FILLET INSPECTED BY NDT AND NO CRACKS FOUND. AN APPROVED REPAIR CARRIED OUT. (TC NR 20070115013)

2007ADP828001

GULSTM

RROYCE

 

SELECTOR VALVE

BYPASSING

8/23/2007

G159

DART5298X

 

159SCH1151

RT MLG

AIRCRAFT WAS ENROUTE, FLYING THE APPROACH FOR RUNWAY 03. ONCE THE CREW PERFORMED THE APPROACH CHECKLIST, AND GEAR DOWN WAS SELECTED BEFORE LANDING CHECKLIST THEY GOT THE RT MAIN AND NOSE GEAR LIGHT ONLY. CREW TRY THE EMERGENCY PROCEDURES DESCRIBED ON CHECKLIST. THIS PROCEDURE DID NOT GET THE (3) GREEN GEAR LIGHTS. AIRCRAFT LANDED WITH (2) GEARS DOWN ON RUNWAY 21, AND SLID INTO THE GRASS. NO INJURIES TO CREW OR PASSENGERS.

2007FA0000759

GULSTM

RROYCE

RROYCE

FAIRING

CRACKED

8/31/2007

GULFSTREAMGV

BR700710A110

 

BRR40289

LP FAN

DURING INSPECTION OF THE AIR INTAKE ROTATING FAIRING, WE FOUND A CRACK BETWEEN THE MOUNT BOLT HOLE AND THE ADJACENT ALIGNMENT PIN HOLE.

2007FA0000697

HUGHES

LYC  

SLICK

CONDENSER

DISCONNECTED

7/11/2007

269C

HIO360D1A

 

M3816

LT MAGNETO

SPRING CLIP ON TERMINAL WIRE CAME OFF ALLOWING WIRE TO DISCONNECT. (K)

2007FA0000688

HUGHES

LYC  

 

BRACKET

LOOSE

7/10/2007

269C

HIO360D1A

 

 

ALTERNATOR

ALTERNATOR BRACKET LOOSE AT ENGINE BOSS. BOLT CAUSES DAMAGE TO ENGINE CRANKCASE WHEN LOOSE. FRETTING OF ARM AND ENGINE CRANKCASE OCCURS. (K)

CA070614001

HUGHES

LYC  

 

DRIVE BELT

SPLIT  

6/8/2007

269C1

HIO360*

 

269A5512

MAIN ROTOR

(CAN) DRIVE BELT AXIAL SPLIT OVER 50 PERCENT OF BELT CIRCUMFERENCE; SPLIT OCCURS UNDER OUTER LAYER OF BELT. DEFECT HAS BEEN FOUND ON (2) OTHER AIRCRAFT OF THE SAME TYPE. NOTE: PLEASE ADVISE IF PHYSICAL INSPECTION IS REQUIRED AS MUST RETURN BELTS TO MANUFACTURER FOR WARRANTY CONSIDERATION. (TC NR 20070614001)

CA070705012

HUGHES

LYC  

 

ALTERNATOR

FAILED

7/5/2007

269C1

HIO360*

 

ALU8521LS

 

(CAN) ALTERNATOR FAILED ON STARTUP. FOUND ROTOR JAMMING AND PULLEY HAD OVERHEATED. LOOSE PARTS HEARD INSIDE ALTERNATOR. NO PREVIOUS INDICATIONS OF IMPENDING FAILURE. (TC NR 20070705012)

CA070612004

HUGHES

LYC  

 

DRIVE BELT

SPLIT  

6/12/2007

269C1

HO360C1A

 

269A5512

MAIN ROTOR

(CAN) DRIVE BELT AXIAL SPLIT OVER 50 PERCENT OF BELT CIRCUMFERENCE; SPLIT OCCURS UNDER OUTER LAYER OF BELT. NOTE: PLEASE ADVISE IF PHYSICAL VERIFICATION IS REQUIRED AS MUST RETURN BELTS TO MFR FOR WARRANTY CONSIDERATION. (TC NR 20070612004)

2007FA0000677

HUGHES

LYC  

 

CYLINDER HEAD

SEPARATED

7/15/2007

269C1

HO360C1A

 

AEL85099IR

ENGINE

2 NR CYLINDER HEAD ASSEMBLY APPEARS TO HAVE FAILED DURING FLIGHT RESULTING IN A SEVERE ENGINE VIBRATION AND A FORCED LANDING. EXAMINATION OF UPPER HALF OF FAILED CYLINDER ASSEMBLY REVEALS THAT A CRACK OCCURRED AND PROPAGATED SYMMETRICALLY AROUND THE CYLINDER APPROXIMATELY .3750 BENEATH WHERE THE CYLINDER BARREL MEETS THE CYLINDER HEAD. NO INTERNAL CYLINDER /PISTON DAMAGE WAS VISUALLY OBSERVED.

2007FA0000667

HUGHES

LYC  

 

CYLINDER HEAD

SEPARATED

7/26/2007

269C1

HO360C1A

 

AEL85099

NR 2 CYLINDER

NR 2 CYLINDER HEAD SEPARATED FROM CYLINDER BARREL IN FLIGHT.

2007FA0000630

HUGHES

ALLSN

 

BLOWER

DAMAGED

5/24/2007

369FF

250C30

 

369D25830101

OIL COOLER

OIL COOLER BLOWER APPEARS TO BE FOD`D OUT. ONE BLADE WAS FOUND ENABLED IN THE HOUSING. THE OUT OF BALANCE SITUATION BROKE ALL (4) BEARING CARRIER LEGS. DAMAGED BLOWER WAS REPLACED AND AC WAS RETURNED TO SERVICE. (K)

2007FA0000701

ISRAEL  

GARRTT

 

ROD  

CRACKED

7/9/2007

1124

TFE731*

 

 

MLG ACTUATOR

(REF CNTRL NR WW1045) RECOVERED AIRCRAFT FROM TAXI WAY AFTER A LANDING WITH NO MLG GREEN LIGHTS. LT GEAR STARTED RETRACTING DURING TAXI. FOUND LT AFT GEAR RETRACT ACTUATOR PISTON ROD BROKEN INSIDE PISTON WHICH HAD CAUSED A MIS-DIRECT OF GEAR DOWN FLOW TO ROUTE INTO RETURN AND UNLOCKING THE GEAR JURY BRACE. THE PISTON ROD HAD BEEN CRACKED FOR A PERIOD OF TIME APPROX .3333 THROUGH PRIOR FAILURE. (K)

2007FA0000703

LEAR

GARRTT

 

STATIC LINE

MISINSTALLED

8/6/2007

35A  

TFE731*

 

 

COCKPIT

THIS RVSM AIRCRAFT HAD AN ALTIMETRY SYSTEM SPLIT. CONTACTED STC GROUP HOLDER FOR PROPER ROUTING OF STATIC SYSTEM PLUMBING. FOUND CO-PILOTS STATIC SYSTEM INSTALLATION WAS NOT CROSS-COUPLED WITH PILOTS SYSTEM. INSTALLED FABRICATED HOSES TO THE CO-PILOTS SYSTEM TO MEET THE INTENT OF STC NR ST00563DE-D IAW MASTER DOCUMENT LIST. CO-PILOTS STATIC SYSTEM NOT INSTALLED CORRECTLY AT STC INSTALLATION OR SYSTEMS HAVE BEEN ALTERED/MODIFIED POST-STC AND DID NOT FOLLOW APPROVED DRAWINGS.

CA070126002

LEAR

GARRTT

 

SQUAT SWITCH

SHORTED

1/25/2007

35LEAR

TFE73122B

 

426EN98

LT MAIN GEAR

(CAN) PRELIMINARY REPORT, SUSPECT THAT THE SHUTTLE VALVE THAT DIRECTS HYDRAULICS TO THE UP- OR DOWN-SIDE OF THE LANDING GEAR WAS STUCK OR BROKEN IN THE UP DIRECTION. WHEN THE L/G WAS SELECTED DOWN ON THE ARRIVAL, NOTHING HAPPENED EXCEPT THE L/G DOORS OPENED THE FIRST TIME, NOTHING AT ALL ON THE SECOND ATTEMPT. THE CREW WENT AROUND AND PUT THE L/G DOWN WITH EMERGENCY SYSTEM. IT WORKED AND THEY HAD THREE GREEN, BUT THE EMERGENCY GEAR EXTENSION LEVER DID NOT LOCK AS IT SHOULD, AND THE L/G RETRACTED ON ITS OWN SHORTLY THEREAFTER! THE EMERGENCY SYSTEM WAS RE-ACTIVATED, THE L/G WENT DOWN AS IT SHOULD AND THE LEVER WAS HELD IN THE DOWN POSITION. THREE GREEN, NORMAL LANDING, AND THE A/C TURNED ONTO A TAXIWAY AND WAS SHUTDOWN. 15 OR 20 MINUTES AFTER SHUTDOWN DURING TROUBLESHOOTING WITH MAINTENANCE, THE CAPTAIN GOT BACK INTO THE COCKPIT TO TURN ON THE BATTERIES AS REQUESTED, AND THE NOSE GEAR RETRACTED (OVER ABOUT 3 OR 4 SECONDS) AND SETTLED ON THE DOORS. (TC NR 20070126002)

CA070223001

LEAR

GARRTT

 

CHECK VALVE

BROKEN

2/20/2007

45LEAR

TFE731*

 

6621000000037

CABIN PRESSURE

(CAN) SHORTLY AFTER TAKEOFF, DURING INITIAL CLIMBOUT, THE CREW NOTICED THAT THE CABIN ALTITUDE RATE OF CLIMB INDICATOR SHOWED 600FT/MIN CLIMB. USUALLY, THE CONTROLLER IS SET TO 400FT/MIN. THEY CONTINUED TO CLIMB AND TO MONITOR THE PRESSURIZATION SYSTEM. A FEW MOMENTS LATER, THE INDICATOR SHOWED A 1500-2000FT/MIN CLIMB. THE CABIN ALTITUDE FOLLOWED THE AIRPLANE ALTITUDE. THE AIRPLANE WAS NOT PRESSURIZING THE CABIN. THE CREW CARRIED OUT THE APPROPRIATE CHECKLIST AND DECIDED TO DIVERT TO THEIR ALTERNATE AIRPORT. MEANWHILE, NO WARNING OR CAUTION INDICATIONS/MESSAGES APPEARED ON EICAS AND THE CREW COULD NOW SMELL KIND OF ODOR OF A OVERHEATED DUCT. THEY NOTICED ALSO THAT NO HEATED/CONDITIONED AIR WAS COMING FROM THEIR FOOTWARMERS/WEMACS. THEY LANDED SAFELY AND CALLED THE MAINTENANCE DEPARTMENT FOR INVESTIGATION. THE MAINTENANCE PERFORMED ENGINE RUNS, OPERATIONAL CHECK OF PRESSURIZATION AND TEMPERATURE CONTROL SYSTEMS AND FINALLY FOUND A 3-IN-DIAMETER CHECK VALVE BROKEN APART IN THE TAILCONE EQUIPMENT BAY. WITH THIS FAILED PART, THE BLEED AIR SYSTEM WAS NOT ABLE TO PRESSURIZE THE CABIN AND ALL THE FLOW OF AIR WAS LEAKING TO THE LESS RESTRICTIVE PATH, I.E. THE TAILCONE AREA. NO FIRE LOOP OR BLEED AIR LEAK DETECTORS WAS FOUND AROUND THE AREA WHERE THE BLEED AIR WAS LEAKING. (TC NR 20070223001)

CA070529007

LEAR

GARRTT

 

WASHER

FAILED

5/29/2007

45LEAR

TFE7312

 

4527102070001

CONTROL COLLUMN

(CAN) DURING A SCHEDULE INSPECTION THE PILOT CONTROL WHEEL WAS FOUND TO HAVE MORE FREE PLAY THAN THE CO-PILOT. UPON FURTHER INVESTIGATION IT WAS FOUND THAT THE TAB WASHER P/N 4527102070-001 WHICH IS SECURING THE NUT P/N NAS1423-20. HAD ONLY ONE TAB BENT, TO ADD TO THE PROBLEM THE TAB WAS IMPROPERLY BENT. AFTER A WHILE THE TAB PERMITTED THE NUT TO BACK OFF ONE FLAT GIVING THE FREE PLAY TO THE CONTROL WHEEL. IT WAS FOUND IN THE MM, CHAPTER 27-10-01 PAGE 202 SECTION B) 9. BEND THE WASHER TABS TO THE NUT FLATS. ONLY ONE TAB WAS BENT, PERMITTING THE NUT TO BACK OFF, THE CO-PILOT CONTROL WHEEL WAS INSPECTED FOR PROPER INSTALLATION AND FOUND TO BE DONE CORRECTLY. THE TAB WASHER WILL BE REPLACED PRIOR TO RETURNING THE AIRCRAFT TO SERVICE. (TC NR 20070529007)

CA070607012

LEAR

GARRTT

 

DISCONNECT UNIT

WORN

5/17/2007

45LEAR

TFE7312

 

4527301000U1

ELEVATOR

(CAN) WHEN AIRCRAFT WAS DOWN FOR A 2400 HR INSPECTION, IT WAS DISCOVERED THAT THERE WAS PLAY BETWEEN THE LT AND RT ELEVATOR (INSPECTION IRN D2730007). AN ELEVATOR FREE-PLAY CHECK WAS C/W AND ELEVATORS WERE FOUND TO BE OUT OF LIMITS. ELEVATOR CONTROL SYSTEM T/S AND FREE PLAY FOUND IN THE AFT ELEVATOR DISCONNECT. PART REPLACED, FREE-PLAY RE-CHECKED AND FOUND TO BE WITHIN LIMITS. (TC NR 20070607012)

CA070608002

LEAR

GARRTT

 

TORQUE TUBE

CORRODED

5/24/2007

45LEAR

TFE7312

 

4555401134011

RUDDER

(CAN) DURING 2400 HR INSPECTION, SB 45-27-24/ DVI IAW 5-19-00-N2720030, CORROSION WAS FOUND INSIDE OF RUDDER TORQUE TUBE. TORQUE TUBE WAS TO BE REPLACED IAW SB45-27-25. WHEN TORQUE TUBE KIT ARRIVED, IT WAS DISCOVERED THAT THE REPLACEMENT TORQUE TUBE WAS MANUFACTURED INCORRECTLY. A SECOND KIT WAS ORDERED AND IT TOO WAS INCORRECT. ORIGINAL TORQUE TUBE CORROSION CLEANED AND REINSTALLED. (TC NR 20070608002)

CA070608003

LEAR

GARRTT

 

ATTACH FITTING

WORN

5/24/2007

45LEAR

TFE7312

 

 

WING TO BODY

(CAN) DURING 2400 HR INSPECTION, IT WAS DISCOVERED THAT A NR OF THE WING TO FUSELAGE LINKS HAD WORN PAINT OFF THE ATTACH FITTINGS. ALL AFFECTED FITTINGS AND LINKS INSPECTED. NO DAMAGE FOUND. MFG ADVISED OF FINDINGS. MFG FOLLOWED UP WITH A LETTER OF APPROVAL TO INSTALL PHENOLIC SPACERS BETWEEN ALL LINKS AND FITTINGS. (TC NR 20070608003)

CA070627003

LEAR

GARRTT

PACIFICSCIEN

SQUIB

INOPERATIVE

6/26/2007

45LEAR

TFE7312

 

3090385659

FIRE BOTTLE

(CAN) WHILE PERFORMING ANOTHER MAINTENANCE TASK IT WAS DISCOVERED THAT THE LOWER (FWD) FIRE BOTTLE SQUIBS WERE NOT INSTALLED IN THE CORRECT POSITION. BOTH FIRE BOTTLES CONTAIN A SQUIB FOR THE LT AND RT ENGINES, THE LOWER NR 1 BOTTLE IS FOR THE FIRST SHOT AND THE UPPER NR 2 BOTTLE IS FOR THE SECOND SHOT. THE LT AND RT SQUIBS ON EACH BOTTLE HAVE A DIFFERENT PN WITH A DIFFERENT CONNECTOR PLUG RECEPTACLE IN ORDER NOT TO ACCIDENTALLY SWAP LT AND RT ENGINES EXTINGUISHING CAPABILITIES. HOWEVER, SINCE THE SQUIBS WERE INSTALLED INCORRECTLY THE FIRST EXTINGUISHING SHOT WOULD HAVE BEEN DIRECTED TO THE WRONG ENGINE. UPON INVESTIGATION IT WAS DISCOVERED THAT THE SQUIBS MAY HAVE BEEN INSTALLED INCORRECTLY AT THE LAST 10-YEAR REPLACEMENT INTERVAL. A FUNCTION CHECK OF THE EXTINGUISHING SYSTEM WAS NOT DUE FOR ANOTHER 230 HOURS. (TC NR 20070627003)

CA070720004

LEAR

GARRTT

 

CURRENT LIMITER

FAILED

7/18/2007

45LEAR

TFE7312

 

EM21542

ELEVATOR

(CAN) WHEN COMPLETING POST FLIGHT INSPECTION (DI), AN AMBER CAS MESSAGE, ELEVATOR DISCONNECT WAS NOTICED ON THE EICAS DISPLAY. ELEVATOR DISCONNECT WAS NOT ACTUATED AT THIS TIME (THIS INDICATES THE ELEVATORS ARE DISCONNECTED ON THE GROUND). ELEVATOR DISCONNECT FUNCTION CHECKED AND IT WAS DISCOVERED THAT THE ELEVATORS WOULD NOT DISCONNECT. SYSTEM TROUBLESHOT AND FOUND THAT CURRENT LIMITER HAD FAILED. A NEW LIMITER WAS ORDERED AND INSTALLED. ELEVATOR DISCONNECT SYSTEM FUNCTION CHECKED SERVICEABLE. MFG NOTIFIED OF FAILURE. (TC NR 20070720004)

2007FA0000736

LEAR

 

 

TIRE

DEFLATED

8/23/2007

60LEAR

 

 

178K481

LT MLG

NOTIFIED BY FLIGHT CREW LT MAIN LANDING GEAR IB AND OB TIRES SEPARATED FROM WHEELS DURING TAXI. TIRES DETACHED FROM WHEEL ASSEMBLIES BUT DID NOT SEPARATED FROM AIRCRAFT. TIRES WERE NOT BLOWN. DAMAGED TIRES AND WHEELS ASSEMBLIES WERE REMOVED. UPON INSPECTION, NO OTHER DAMAGES NOTED ON LANDING GEAR OR SURROUNDING STRUCTURE. NO FOD DAMAGE TO AIRCRAFT. REPLACED WITH SERVICEABLE WHEELS/TIRES ASSEMBLIES.

CA070718002

LEAR

PWA  

 

ACTUATOR

FAULTY

7/17/2007

60LEAR

PW305A

 

2317100016

NLG 

(CAN) DURING ARRIVAL, NOSE LANDING GEAR WOULD NOT INDICATE DOWN AND LOCK. ALTERNATE GEAR EXTENSION WAS PERFORMED. AIRCRAFT WAS FERRIED, FUNCTIONAL CHECK OF THE EMERGENCY GEAR EXTENSION WAS CHECKED, NOSE GEAR STAYED IN WHEEL WELL. FREE FALL PRESSURE TESTED AND FOUND TO BE BETWEEN 85 TO 90 LBS (MAX LIMIT 20 LBS). GEAR DOOR AND GEAR ACTUATOR WAS DISCONNECTED AND GEAR FREE FALL WAS CHECKED AND FOUND TO BE WITHIN LIMITS. SUSPECT FAULTY INTERNAL GEAR ACTUATOR LOCKING SLEEVE. NOSE GEAR ACTUATOR REPLACED. FUNCTIONAL CHECK CARRIED OUT-SERVICEABLE. (TC NR 20070718002)

2007FA0000672

LET  

 

 

BRIDGE

CRACKED

7/27/2007

L23  

 

 

A741210N

ZONE 100

ON JULY 23, 2007 DURING A ROUTINE DYE-PENETRANT INSPECTION ON TG-10B (L-23 SUPER BLANIK, S/N 029013) CRACKS WERE DISCOVERED AT SEVERAL WELDS ON THE A741 210N BRIDGE ASSEMBLY. IT IS A MAINTENANCE MANUAL REQUIREMENT THAT THIS PART BE DYE-PENETRANT INSPECTED EVERY 1000 HOURS. A REPLACEMENT BRIDGE ASSEMBLY WAS CANNIBALIZED FROM ANOTHER TG-10B (L23, S/N 029015) IN AN EFFORT TO PLACE THE FIRST NOTED AIRCRAFT BACK IN SERVICE. AS A PRECAUTIONARY STEP, WE DECIDED TO DYE-PENETRANT THE CANNIBALIZED ASSEMBLY AND DISCOVERED IT TOO WAS CRACKED. AT THIS POINT IT WAS DECIDED TO INSPECT THE REST OF THE AIRCRAFT HERE AT USAFA. 12 OUT OF 12 AIRCRAFT REVEALED CRACKS.

2007FA0000671

LET  

 

 

BRIDGE

CRACKED

7/27/2007

L23  

 

 

A741210N

 

DURING A ROUTINE DYE-PENETRANT INSPECTION ON TG-10B CRACKS WERE DISCOVERED AT SEVERAL WELDS ON THE A741 210N BRIDGE ASSEMBLY. A REPLACEMENT BRIDGE ASSY CANNIBALIZED FROM ANOTHER TG-10B IN AN EFFORT TO PLACE THE FIRST NOTED AIRCRAFT BACK IN SERVICE. AS A PRECAUTIONARY STEP, DECIDED TO DYE-PENETRANT THE CANNIBALIZED ASSEMBLY AND DISCOVERED IT TOO WAS CRACKED. DECIDED TO INSPECT THE REST OF THE ACFT. 12 OUT OF 12 ACFT REVEALED CRACKS.

CA070730005

LKHEED

ALLSN

 

STRUCTURE

SEPARATED

7/28/2007

188C

501D13

 

 

TE FLAPS

(CAN) FIRE SUPPRESSION OPERATIONS IN RUGGED MOUNTAINOUS TERRAIN. FINISHED LAST OF 4 DROPS. APPLIED MAX POWER AND FLAPS TO 78 PERCENT AND PROCEEDED WITH CLEAN UP CHECKLIST. NOTICED ABNORMAL OF CONTROL COLUMN ( MORE AILERON). ADJUSTED TRIMS AND POWER SETTINGS. PNF WENT TO THE BACK NOTICED DAMAGE TO RT OB PORTION OF FLAP. PILOT SLOWED AIRCRAFT. ADVISED FSS OF PROBLEM. PILOT RAN FLAPLESS CHECKLIST AND REQUESTED EMERGENCY VEHICLES. PILOT SLOWED AIRCRAFT TO DETERMINE CONTROLLABILITY. REVIEWED BRAKE FIRE PROCEDURES PRIOR TO LANDING AND THEN FLEW APPROACH AT MARKED BUG TO RUNWAY AND LANDED WITHOUT INCIDENT. MAINTENANCE FOUND 5 FT OF THE RT FLAP PANEL SEPARATED FROM THE ASSEMBLY AND TRAILING ON THE FLAP RAIL. MAINTENANCE CONDUCTED A ASYMMETRY CHECK AND THE SYSTEM WORKED NORMAL. THE FLAP PANEL WILL BE ANALYZED WHEN RETURNED TO THE MAIN MAINTENANCE BASE. (TC NR 20070730005)

CA070715001

LKHEED

ALLSN

 

FITTING

LEAKING

7/14/2007

188C

501D13

 

 

OIL SYSTEM

(CAN) THE CREW NOTICED A LOSS OF OIL QUANTITY ON THE NR 3 ENGINE. THIS LOSS WAS FOLLOWED BY A FLUCTUATION IN THE REDUCTION GEARBOX PRESSURE. THE ENGINE WAS SHUTDOWN PRIOR TO LANDING. IT WAS DETERMININED THAT A FITTING ON THE TURBINE SECTION WAS LEAKING. THERE WAS 3-4 GALLONS OF OIL REMAINING IN THE RESEVOIR, THE AIRCRAFT WAS FERRIED FOR AN ENGINE CHANGE. (TC NR 20070715001)

CA070720008

LKHEED

ALLSN

 

COMPRESSOR

ERODED

7/18/2007

382G

501D22A

 

 

ENGINE

(CAN) DEPARTING DESTINATION, THE CREW NOTED A COMPRESSOR STALL CONDITION ASSOCIATED WITH HIGH TGT ON NR 1 ENGINE. THE CREW CARRIED OUT A PRECAUTIONARY SHUTDOWN, RETURNED TO POINT OF DEPARTURE AND LANDED WITHOUT FURTHER PROBLEM. MAINTENANCE FOUND SIGNIFICANT EROSION IN THE COMPRESSOR 5TH AND 10TH STAGE BY VISUAL INSPECTION AND ELECTED TO REPLACE THE ENGINE. (TC NR 20070720008)

2007FA0000661

MAULE

CONT

 

FUEL

CONTAMINATED

7/1/2007

M5210C

IO360A

 

 

 

WHILE PERFORMING BI-ANNUAL REVIEW. ON LAST TAKEOFF, THE ENGINE BEGAN TO RUN ROUGH. ENGINE DRIVEN FUEL PUMP FAILED AND INSTALLED A FRESHLY OVERHAULED PUMP. ATTEMPTED A RUN UP WITH THE SECOND PUMP AND FOUND THE COVER PLATE AT THE MIXTURE CONTROL LEVER TO BE LEAKING. REMOVED SECOND PUMP. OVERHAUL SHOP FOUND EVIDENCE OF WATER IN THE FUEL SYSTEM, LIGHT RUST IN THE ORIGINAL PUMP BODY, AND A WHITE FILM UNDER THE PRESSURE VALVE SEAT THAT DISINTEGRATED INTO A WHITE POWDER WHEN IT DRIED. THE PUMP WAS NOT ABLE TO PRODUCE THE PROPER PRESSURE WITH THIS FILM HOLDING THE VALVE OPEN. DECIDED TO FLUSH THE FUEL SYSTEM AND TRY TO DETERMINE THE SOURCE OF CONTAMINATION. FLUSHED ALL OF THE FUEL LINES. THERE WAS LIGHT SURFACE CORROSION ON THE INNER AND OUTER SURFACES OF THE STAND PIPE THAT DUMPS THE INCOMING FUEL INTO THE BOTTOM OF THE BOWL WHERE THE BOTTOM OF THE OVAL SHAPED FILTER CONTACTS THE STAND PIPE. WE WERE UNABLE TO PUSH A PICK THRU THE STAND PIPE IN THE CORRODED AREAS SO WE DON’T FEEL THE PIPE WAS COMPROMISED, HOWEVER THE CORROSION ON THE INSIDE OF THE PIPE MAY HAVE BEEN THE SOURCE OF THE WHITE POWDER FOUND IN THE FUEL PUMP. NO OTHER WHITE SUBSTANCES WERE FOUND WHILE FLUSHING THE SYSTEM. UNABLE TO DETERMINE HOW ANY OF THE OTHER CONTAMINANTS THAT WERE FOUND ON THE ENGINE SIDE OF THE GASCOLATOR MADE IT TO THAT POINT. FILTER SCREEN WAS PROPERLY INSTALLED AND DID NOT HAVE ANY HOLES OR TEARS. THE GASCOLATOR HOUSING WAS INSTALLED WITH THE PROPER ORIENTATION TO THE FUEL SYSTEM. HOSES WERE IN GOOD CONDITION AND THE AIRCRAFT IS NOT RUN ON AUTO GAS. (K)

2007FA0000734

MOONEY

CONT

 

VOLT REGULATOR

FAILED

7/24/2006

M20R

IO550*

 

800397501

 

THE INABILITY OF THE VOLTAGE REGULATOR (PN 800397-501, SN 0165) TO CONTROLTHE OUTPUT OF THE ALTERNATOR WHEN THE BATTERY SWITCH WAS TOGGLED BETWEEN THE NR1 AND NR 2 BATTERY, IN FLIGHT. (K)

CA070628003

MRCHTI

PWA  

 

BOLT

FAILED

5/16/2007

S20522R

PT6A65AR

 

MS949034

FIRST STAGE

(CAN) ENGINE S/N PCE 97543 WAS REMOVED SUBSEQUENT TO IN-FLIGHT SHUTDOWN AFTER THE ENGINE OIL PRESSURE DROPPED TO (0) IN FLIGHT. METAL WAS FOUND IN THE OIL FILTER AND RGB DURING GROUND CHECKS PRIOR TO ENGINE REMOVAL. DURING INVESTIGATION DISMANTLE OF THE POWER SECTION, (2) OF (6) FIRST-STAGE REDUCTION CARRIER ASSEMBLY MACHINE HEX BOLTS (IPC P/N 3032844, CH. 72-11-00, FIGURE 4, ITEM 200, P/N MS9490-34) WERE FOUND WITHOUT THE BOLT HEADS ATTACHED (REFERENCE FIGURE 1). NOTE THAT THE CARRIER HEX BOLTS SECURE THE FIRST-STAGE CARRIER AND THE FIRST-STAGE REDUCTION SPLINED ADAPTER. THERE ARE A QUANTITY OF SIX HEX BOLTS INSTALLED WITH KEYWASHERS AND ARE TORQUED 75 TO 85 IN.LB. ENGINE OVERHAUL RECORDS INDICATED THAT QUANTITY SIX BOLTS WERE REPLACED WITH NEW ONES DURING ENGINE OVERHAUL IN JULY 2006. THIS IS THE SIXTH CASE THAT HAS COME TO OUR ATTENTION SINCE APRIL 2004. (TC NR 20070628003)

CA070718004

MTSBSI

GARRTT

 

LEVER

LOOSE

7/14/2007

MU2B36

TPE33110

 

022A431113

PROP PITCH

(CAN) THE PPC LEVER WAS FOUND SEPARATED FROM THE PPC INPUT SHAFT. THE BOLT WAS OF THE CORRECT P/N, YET WAS THREAD BOUND WITHOUT PRODUCING ENOUGH TENSION TO HOLD THE PPC ARM ONTO THE PPC SHAFT. THE PPC ARM WAS REINSTALLED AND A WASHER WAS PLACED UNDER THE HEAD OF THE BOLT TO PROVIDE A BETTER GRIP ON THE SPLINED SHAFT. THE PPC INPUT SHAFT HAS A THREADED BORE WHICH WOULD ALLOW THE USE OF AN ADDITIONAL BOLT AND WASHER AS A BACKUP RETAINER FOR THE PPC ARM IN THE EVENT THAT THE ARM WERE TO LOOSEN OFF. THE AIRFRAME IPC DOES NOT SHOW A BOLT FOR THIS PURPOSE. (TC NR 20070718004)

R0240301

MTSBSI

 

 

BRACKET

CRACKED

8/14/2007

MU2B60

 

 

B3493

PROPELLER

FIVE B-3493 START LOCK BRACKETS WERE FOUND DURING PENETRANT INSPECTION TO BE CRACKED AT THE SAME LOCATION. CRACKS ARE LOCATED ON THE EXTERIOR START PIN BORE NEXT TO THE SPINNER MOUNTING BOLT RELIEF CUT-OUT. THIS BRACKET IS PART OF THE 830-34L START LOCK UNIT INSTALLED ON 4-BLADED MU-2S.

2007FA0000730

PIAGIO

 

 

ANTENNA

SEPARATED

8/13/2007

P180

 

 

ADS430101AC

FUSELAGE

RADAR ALTIMETER REPORTED INOPERATIVE. FOUND ANTENNA SENSOR GONE FROM THE BASE, LEAVING .2500 INCH HOLE THROUGH THE COAX CONNECTION. THE FLAT ANTENNA MOUNTS TO A CURVED FUSELAGE WITHOUT CONTOUR ADAPTATION. (K)

CA070704011

PIAGIO

PWA  

 

OIL SYSTEM

OVERTEMP

5/14/2007

P180

PT6A66

 

 

ENGINE

(CAN) IN FLIGHT, THE ENGINE OIL TEMPERATURE WAS SEEN TO INCREASE AND THE ENGINE WAS SHUTDOWN. POST-FLIGHT INSPECTION REVEALED OIL LEAKAGE AT THE ENGINE (C) FLANGE. MFG WILL INVESTIGATE THE EVENT AND ADVISE OF ROOT CAUSE ONCE ESTABLISHED. (TC NR 20070704011)

CA070612001

PILATS

GARRTT

 

SWITCH

MALFUNCTIONED

5/29/2007

PC1245

TPE33112UHR

 

 

MLG ACTUATOR

(CAN) CREW REPORTED THE LT MAIN LANDING GEAR DOWN AND LOCK INDICATION WAS SHOWING (IN TRANSIT) WHEN SELECTED DOWN. THE SYSTEM WAS TROUBLESHOT TO THE DOWNLOCK INDICATOR SWITCH IN THE GEAR ACTUATOR. ACTUATOR REPLACED AND AIRCRAFT RETURNED TO SERVICE. (TC NR 20070612001)

CA070611001

PILATS

PWA  

 

PUMP

MALFUNCTIONED

6/8/2007

PC1245

PT6A67B

 

9638411403

FUEL BOOST

(CAN) WHILE PERFORMING A DEFUEL OF AIRCRAFT TO PERFORM SCHEDULED MAINTENANCE, RT WING FUEL BOOST PUMP POPPED CIRCUIT BREAKER AFTER 3 MINUTES OF OPERATION DEFUELING AIRCRAFT. PUMP WAS ALLOWED TO SIT FOR 10 MINUTES AND C/B RESET AND PUMP WOULD AGAIN WORK FOR 3 MINUTES. THIS HAPPENED 3 TIMES UNTIL DEFUEL WAS COMPLETE. PUMP WAS REPLACED WITH O/H UNIT. TESTED SATISFACTORY (TC NR 20070611001)

CA070113001

PILATS

PWA  

 

HINGE

CORRODED

1/2/2007

PC1245

PT6A67B

 

5531412027

PAX DOOR

(CAN) AFTER A HEADS UP CONDITION FROM ANOTHER RCMP AIR SECTION. AN INSPECTION OF CONDITION WAS CARRIED OUT ON MPI. THE PART INSPECTED WAS FOUND SEVERELY CORRODED AND IF LT UNCHECKED COULD AFFECT THE INTEGRITY OF THE CABIN DOOR FRAME. THE HINGE PLATE MOUNTED AT THE BASE OF THE AIRSTAIR DOOR OPENING AND IS RIVETED TO THE DOOR SILL ASSY. APPROXIMATELY 50 PERCENT OF THE HINGE WAS AFFECTED BY CORROSION. THE CAUSE IS THOUGHT TO BE FROM SALT ON PASSENGER BOOTS IN WINTER OPERATIONS. THE HINGE IS DIFFICULT TO INSPECT UNTIL DERIVATE FROM THE DOOR SILL ASSY.THE MFG HAD SEALED BETWEEN THE HINGE ASSY AND THE DOOR SILL WITH PRC AND THIS PREVENTED DOOR SILL DAMAGE. (TC NR 20070113001)

CA070115001

PILATS

PWA  

 

INSULATION

DETERIORATED

1/9/2007

PC1245

PT6A67B

 

 

FUSELAGE

(CAN) DURING AN INTERIOR REFURBISHMENT IT WAS NOTED THE FUSELAGE INSULATION FROM THE CABIN FLOOR AND UP HAD BADLY DEGRADED INSULATION BAGS. THE THERMAL ACOUSTIC FOAM IS SURROUNDED BY BAGS WITH A VAPOR FOIL ON THE INNER SURFACE AND SEALED TO A THIN LATEX TYPE BARRIER ON THE OB SURFACE. THE OUTER SURFACE HAD RUPTURED AND DEGRADED ON ALL OUTER SURFACES OF THE INSULATION BAGS. ALL CABIN INSULATION HAD TO BE REMOVED AND REPAIRED WITH THE APPROVED TAPE. IF LEFT UNCHECKED THIS COULD ADD A CORROSION PROBLEM WITHIN THE FUSELAGE AS MOISTURE HAD WICKED INTO THE INSULATION IN SOME AREAS. IF THE A/C WAS NOT HANGARED EACH NIGHT FOR DRYING IT COULD POSE A WEIGHT PROBLEM THAT WOULD BE UNKNOWN TO FLIGHT AND MAINTENANCE CREWS. WE CONSUMED MORE THAN TWENTY MAN HOURS WITH THE INTERIOR PREVIOUSLY REMOVED TO COMPLETE THIS TASK. (TC NR 20070115001)

CA070528002

PILATS

PWA  

 

RELAY

FAULTY

5/11/2007

PC1245

PT6A67B

 

9740926112

MLG 

(CAN) ON APPROACH THE LANDING GEAR WAS SELECTED DOWN. THE NOSE LANDING GEAR IN TRANSIT LIGHT WAS SLOW TO EXTINGUISH. UPON MAINTENANCE TROUBLESHOOTING THE HYDRAULIC PUMP WAS FOUND TO BE INTERMIITTENTLY CUTTING OUT. THE LANDING GEAR RELAY WAS REPLACED AND NO FURTHER ADNORMALITIES WERE REPORTED. (TC NR 20070528002)

CA070227010

PILATS

PWA  

 

CONTROL PANEL

FAILED

2/23/2007

PC1245

PT6A67B

 

0710143931

EFIS 

(CAN) MOVING THE HEADING KNOB ON THE CONTROL PANEL WOULD CAUSE A FAILURE INDICATION (RED X) THROUGH THE HEADING BUG, AND A TD WARNING ON THE BOTTOM RT CORNER OF THE EFIS SCREEN. THE CONTROL PANEL WAS REPLACED. (TC NR 20070227010)

CA070227012

PILATS

PWA  

 

RECEIVER

ERRATIC

2/23/2007

PC1245

PT6A67B

 

066107214

ADF 

(CAN) THE VOLUME ON THE ADF WAS VERY HARD TO ADJUST AND ERRATIC. ADF RECEIVER REPLACED (TC NR 20070227012)

CA070202011

PILATS

PWA  

PILATS

BARREL NUT

CORRODED

2/1/2007

PC1245

PT6A67B

532201203

5322012165

NLG 

(CAN) PILOT REPORTED THAT ON OCCASION DURING EXTENSION OF LANDING GEAR THAT A LOUD CLUNK WAS HEARD IN NOSE GEAR AREA.DURING A TEARDOWN OF NOSE LANDING GEAR TO REPLACE INTERNAL SEALS ,IT WAS NOTED THAT ON THE INNER GROOVE OF BARREL NUT ,THAT SUPPORTS A PHENOLIC GUIDE RING THAT CORROSION WAS OCCURING IN THE ALUMINIUM BARRLE NUT.THIS CORROSION PUT SO MUCH PRESSURE ON BACKSIDE OF GUIDE RING THAT THE RING WAS CLAMPING TO OLEO STRUT NOT ALLOWING THE STRUT TO FULLY EXTEND PRIOR TO RETRACTION OF GEAR. WHEN GEAR WAS LOWERED IN COLD FLIGHT CONDITIONS THE NOSE FORK WOULD CONTACT GEAR RETRACT MECHANISM ON EXITING GEAR WELL CAUSING CLUNK. REMOVAL AND TREATMENT OF CORROSION, CLEANING OF GUIDE RING ALLOWED FREE MOVEMENT OF OLEO STRUT.GUIDE RING PN 532.20.12.200 (TC NR 20070202011)

CA070202001

PILATS

PWA  

 

COWLING

DAMAGED

1/30/2007

PC1245

PT6A67B

 

5711012091

 

(CAN) AFTER TAKEOFF THE PILOTS NOTICED THAT THE TOP FRONT COWLING WAS LIFTING OFF AT THE REAR. THEY RETURNED TO THE FIELD AND DURING THE FLARE THE COWLING DEPARTED THE AIRCRAFT, STRIKING AND DAMAGING THE PROP REQUIRING ITS DISASSEMBLY AND RT WING DAMAGING THE OB DEICE BOOT. THE POWER SECTION WAS REMOVED FOR A PROP STRIKE INSPECTION. MAINTENANCE HAD BEEN ACCOMPLISHED THE PREVIOUS EVENING WHERE THAT COWLING HAD BEEN REMOVED AND REINSTALLED. THE (4) LATCHES APPEARED SECURE TO THE AME AND THE PILOTS ON THEIR WALK AROUND. THERE IS NO VISUAL AID ON THIS COWLING DESIGN OTHER THEN THE LATCH BEING (FLUSH) TO INDICATE TO THE PILOT OR TECHNICIAN THAT THE LATCH IS SECURED. PREVIOUS EXPERIENCE HAS SHOWN THAT THE DIFFERENCE IN WHAT A PROPERLY SECURED LATCH LOOKS LIKE AND IMPROPERLY SECURED LATCH LOOKS LIKE CAN BE MIMINAL BY SIGHT. THE LATCH RECEPTACLES ON THE RECOVERED TOP COWLING APPEARED TO HAVE NOMINAL WEAR AS WELL AS THE LATCHES ON THE BOTTOM FRONT COWL THAT STAYED ON THE AIRCRAFT. (TC NR 20070202001)

CA070622004

PILATS

PWA  

 

BLOWER

INOPERATIVE

6/19/2007

PC1245

PT6A67B

 

9599022154

RIGHT

(CAN) RT VENTILATION BLOWER WOULD NOT OPERATE WHEN SWITCHED ON. REPLACED WITH NEW. (TC NR 20070622004)

CA070717015

PILATS

PWA  

 

FUEL CONTROL

MALFUNCTIONED

7/11/2007

PC1245

PT6A67B

 

806304101A

ENGINE

(CAN) ON TAKEOFF, THE FULL ENGINE POWER (43 PSI) WAS NOT ACHIEVABLE, 35 PSI WAS ALL THE ENGINE WOULD PRODUCE. THE PILOT REPORTED ENGINE WAS NOT CONTROLABLE WITH POWER LEVER WHEN PULLED TO IDLE (ENGINE AT 35 PSI TORQUE). ADVISED NOT TO TRY AND START THE ENGINE AND TO REPLACE THE FCU. FCU WAS REPLACED AND ALL ENGINE RUNS CHECKED SERVICEABLE. (TC NR 20070717015)

CA070720006

PILATS

PWA  

 

BRAKE ASSY

FAILED

7/7/2007

PC1245

PT6A67B

 

03024400

MLG 

(CAN) WHILE AIRCRAFT WAS BEING PUSHED BACK USING A TOWING DEVICE PART OF THE BRAKE ROTORS CAME LOOSE ON THE RT MLG AND PUNCTURED THE RIM ASSEMBLY. CAUSED THE TIRE TO GO FLAT. BRAKE DISC AND WHEEL. REPLACED AND THE AIRCRAFT WAS RETURNED TO SERVICE. WAS INFORMED BY THE LOCAL DEALER THAT THE ROTORS USED IN THIS BRAKE DISC WERE SUPPOSED TO BE NEW AND IMPROVED JUST FOR THIS SITUATION. (TC NR 20070720006)

CA070730002

PILATS

PWA  

 

BRAKE DISC

BROKEN

7/23/2007

PC1245

PT6A67B

 

30244

MLG 

(CAN) AT THE TIME OF TAKEOFF THE WHEEL OF BLOCKED LT A AND A CAUSED THE EXIT OF TRACK OF THE APPARATUS. APPARATUS A DOES NOT SUFFER ANY DAMAGE AND AT SUMMER MOVED TO THE AIR OF PARKING. A TEAM OF MAINTENANCE OF THE COMPANY EAST GONE ON THE SPOT AND A FOUND THAT A DISC OF THE LT BRAKE WAS BROKEN. REPLACED BRAKE. (TC NR 20070730002)

2007FA0000693

PIPER

LYC  

 

BOLT

LOOSE

6/21/2007

PA18150

O360*

 

 

PROPELLER

PILOT REPORTED SLIGHT VIBRATION DURING FLIGHT OF APPROX (1) HOUR. WHEN POWER WAS REDUCED FOR LANDING, VIBRATION BECAME MORE EVIDENT. INITIAL INSP FOUND (1) PROP BOLT HAD COME OUT FWD AND THROUGH SPINNER AND PROP WAS LOOSE. WITH REMOVAL OF SPINNER, FOUND (2) BOLTS BACKED OUT, (1) THROUGH THE SPINNER AND (1) NEXT TO IT. (2) BOLTS REMAINED SAFETIED, BUT NOT TIGHT. THE REMAINING PAIR OF BOLTS, THE SAFETY WIRE WAS BROKEN BETWEEN THE BOLTS AND THE BOLTS WERE BACKED OUT APPROX (1) INCH. AFTER COMPLETE REMOVAL OF PROP, WHICH REQUIRED CUTTING THE HEAD OFF OF (1) BOLT, THE ATTACHMENT BUSHING FOR THIS BOLT WAS BROKEN OFF FLUSH WITH THE CRANKSHAFT FLANGE. ANOTHER ATTACHMENT BUSHING WAS ALSO BROKEN OFF, FLUSH WITH THE CRANKSHAFT FLANGE. ORIGINAL METAL PROP, MODEL 76EM8-0-56, SN: 31720K, WAS REMOVED FROM THE AIRCRAFT ON JULY 20, 2006 AND THE CAPTIONED WOOD PROP, MODEL W80CM845, SN AF5140, WAS INSTALLED IAW STC SA 192NW AND MFG (WOOD PROPELLERS INSTALLATION AND MAINTENANCE) INSTRUCTIONS AND TORQUED IAW TABLE (1). PROP MAINT BOLT TORQUE WAS COMPLIED WITH SINCE INSTALLATION. (K)

2007FA0000722

PIPER

LYC  

PIPER

HORN

DAMAGED

8/12/2007

PA18180

O320*

 

 

ELEVATOR

AFTER DEPARTURE PILOT NOTED UNUSUAL STICK RESTRICTION AND ABORTED TOW OF GLIDER. RETURNED FOR LANDING. UPON INSPECTION THE LOWER ARM/HORN OF THE RT ELEVATOR HORN HAD BROKEN. ALL (3) OTHER ARMS WERE UNDAMAGED AND SHOWED NO SIGN OF CRACKS. BOLTS WERE INTACT AND HOLDING CONTROL CABLE.

2007FA0000660

PIPER

LYC  

 

EXHAUST VALVE

BROKEN

5/26/2007

PA28140

O320E2A

 

 

NR 4 CYLINDER

NR 4 EXHAUST VALVE BROKE DURING FLIGHT, DAMAGING PISTON CAUSING OIL TO LEAK OUT EXHAUST PORT CREATING OIL SMOKE. (K)

2007FA0000705

PIPER

LYC  

 

ALTERNATOR

FAILED

8/9/2007

PA28161

O320*

 

KELLY4111810

ENGINE

ALTERNATOR FAILED AFTER 17.6 HOURS.

2007FA0000706

PIPER

LYC  

 

ALTERNATOR

FAILED

8/9/2007

PA28161

O320*

 

KELLY4111810

ENGINE

ALTERNATOR FAIL AFTER 174 HOURS OF NORMAL OPERATION.

CA070713003

PIPER

LYC  

 

SERVO

LEAKING

7/6/2007

PA31

TIO540A2C

 

252416314

FUEL INJECTOR

(CAN) FUEL INJECTOR SERVO ON LT ENGINE FOUND TO HAVE AN INTERNAL LEAK AND WOULD NOT SHUTDOWN PROPERLY. SERVO WAS REMOVED AN OVERHAULED UNIT INSTALLED ENGINE GROUND RUN. (TC NR 20070713003)

CA070621004

PIPER

LYC  

 

CABLE

SEPARATED

6/11/2007

PA31350

TIO540J2BD

 

4173478

ELEVATOR TRIM

(CAN) PILOT REPORTED ELEVATOR TRIM VERY STIFF WHILE IN FLIGHT, THEN FREE AFTER SEVERAL ATTEMPTS. MAINT INVESTIGATION REVEALED TRIM CABLE P/N 41734-78 SEPARATED AT THE TRIM SERVO P/N 1C469-6-498. CABLE WAS REPLACED AND SYSTEM RIGGED IAW MM 5-32. CABLE INSPECTION DID NOT REVEAL ANY UNUSUAL WEAR OR FRAYING AT THE SEPARATED ENDS. CABLE WAS SHREDDED AND APPEARED TO BE TORN APART. FURTHER INVESTIGATION BY AVIONICS REPAIR STATION REVEALED THAT THE ELEVATOR ELECTRIC/AP TRIM SERVO CLUTCH RELEASE MECHANISM WAS INTERMITTENT. SERVO WAS REPAIRED AND OPERATION CHECKED SERVICEABLE. (TC NR 20070621004)

2007FA0000748

PIPER

PWA  

 

TUBE

CRACKED

7/18/2007

PA31T

PT6A28

 

3011849

LT ENGINE

FUEL LEAK NOTED ON SHUTDOWN. FUEL TUBE P/N 3011849 WAS CRACKED AT CONNECTION TO START CONTROL UNIT.

2007FA0000729

PIPER

CONT

CONT

BUSHING

MISINSTALLED

8/3/2007

PA34220T

TSIO360RB

 

538684

CONNECTING ROD

DURING THE PROCESS OF INSPECTING (6 EA) CONNECTING RODS IAW SB 07-1 AND SB 00-3, IT WAS FOUND THAT ALL WRIST PIN BUSHINGS WERE INSTALLED NOT IAW THEIR POSITIONS AS REQUIRED IN THE APPLICABLE SB AS REFERENCED. SPLIT LINE OF BUSHING ON WRONG SIDE OF CENTERLINE. PARTS AS RECEIVED FROM MFG. (K)

2007FA0000657

PIPER

 

 

ROLL PIN

SHEARED

6/29/2007

PA421000

 

 

480572

RUDDER PEDAL

PILOTS RT RUDDER PEDAL ROLL PINS SHEARED. REFERENCE IPC PN 761792, FIG. 103, INDEX 14, PN 480572. FAILURE MAY CAUSE LOSS OF DIRECTIONAL CONTROL OR BRAKING ACTION DURING GROUND OPERATION. (K)

CA070605005

PIPER

PWA  

 

ATTACH BOLT

BENT

6/5/2007

PA42720

PT6A61

 

4178902

MLG ACTUATOR

(CAN) CONTINUOUS PROBLEM OF PREMATURE WEAR AND INDICATIONS OF STRESS ON MAIN LANDING GEAR ACTUATOR ATTACH HARDWARE. LOWER FORK BOLT PN 41789-02 AND UPPER ACTUATOR ATTACH BOLT 401-195 (AN5-17A) (BOTH LIFE LIMITED BY MFG INSPECTION PROGRAM) SHOW SIGNS OF BENDING AND/OR WEAR VIRTUALLY EACH DETAILED GEAR INSPECTION (TYPICALLY 200 AIRCRAFT HOURS). THESE PARTS ARE REMOVED AND CLOSELY INSPECTED EACH GEAR INSPECTION AND TYPICALLY REPLACED AT FAR LOWER INTERVALS THAN THE PUBLISHED LIFE LIMITS. (TC NR 20070605005)

2007FA0000699

RAYTHN

 

 

SHUTOFF VALVE

JAMMED

7/3/2007

390  

 

 

EM0159

HYD SYSTEM

PILOT REPORTED RT ENGINE HYDRAULIC SHUTOFF VALVE WOULD NOT CLOSE FOLLOWING PREFLIGHT CHECKS. FOUND VALVE ASSY STUCK OPEN. REPLACED VALVE ASSY WITH NEW VALVE ASSY, OPERATIONS NORMAL. VALVE ASSY (PN 45AS65014003) HAVE NOTICED THESE VALVE ASSY TENDING TO FAIL WITH SHORT TIE SINCE NEW IN MFG INSTALLATIONS. VALVE ASSY SEEMS FAIRLY RELAIBLE WHEN USED IN OTHER INSTALLATIONS. (K)

GC4N200700001

RAYTHN

WILINT

 

ACTUATOR

FAULTED

8/24/2007

390  

FJ442A

 

 

NLG 

AFTER COMPLAINT FROM THE PILOT OF NOT GETTING A NOSE LANDING GEAR DOWN LIGHT STRAIT AWAY, PLACED THE AIRCRAFT ON JACKS AND CARRIED OUT 4 RETRACTIONS WHICH RESULTED IN 100 PERCENT FAILURE OF THE NOSE LANDING GEAR FULLY EXTENDING, AFTER FAULT FINDING WE BELIEVE THE NOSE LANDING GEAR ACTUATOR TO BE FAULTY, A PART IS ON ORDER FROM MFG.

2007FA0000726

RAYTHN

 

 

DOWNLOCK SWITCH

FALSE INDICATION

7/3/2007

C90GT

 

 

903610373

MLG 

PILOT REPORTED LT MAIN LANDING GEAR DOWN AND LOCKED INDICATION WITH LANDING GEAR RETRACTED. FOUND SWITCH ASSY INDICATOR SHOWING GREEN DOWN AND LOCKED INDICATION IN GEAR RETRACTED POSITION. REPLACED SWITCH ASSY WITH NEW UNIT. LANDING GEAR RETRACTION/ EXTENSION SYSTEM TESTS NORMAL. (K)

2007FA0000674

RAYTHN

 

 

LINE

RUPTURED

7/17/2007

HAWKER800XP

 

 

SA7670024001

HYD SYSTEM

FLEXIBLE HYDRAULIC LINE TO THE RT MAIN GEAR IB DOOR ACTUATOR RUPTURED IN FLIGHT. CREW EXTENDED LANDING GEAR AND FLAPS USING THE AUXILIARY HYDRAULIC SYSTEM AND LANDED WITHOUT INCIDENT. DURING INSPECTION BY MAINTENANCE DEPARTMENT NO APPARENT CAUSE WAS DETERMINED FOR THE LINE FAILURE. MFG HAS BEEN ADVISED OF THE DEFECT. NEW HYDRAULIC LINE WAS INSTALLED, SYSTEM WAS SERVICED WITH FLUID AND BLED, AIRCRAFT WAS RETURNED TO SERVICE.

2007FA0000632

RAYTHN

GARRTT

 

LINK ROD

CRACKED

6/29/2007

HAWKER800XP

TFE731*

 

545300319

THRUST REVERSER

PERFORMED EDDY CURRENT INSPECTION OF 8 EA THRUST REVERSER LINK ROD. FOUND A CRACK IN (1) LINK ROD. VERIFIED FINDING USING MAGNETIC PARTICLE INSP METHOD. DURING MP INSP, NOTED ANOTHER CRACK, NOT DETECTED USING EDDY CURRENT. DECIDED TO PERFORM MP INSP OF ALL RODS AND FOUND 3 MORE CRACKED. CRACKS APPEAR TO BE ON THE INNER SURFACE AND WOULD NOT BE DETECTABLE WITH NDT INSP PRESCRIBED IN THE MM. CURRENT INSPECTION REQUIREMENTS ARE NOT ADEQUATE FOR FINDING THESE TYPES OF DEFECTS. CRACKS IDENTIFIED ARE ORIENTED LONGITUDINALLY O THE RODS AND VARY IN LENGTH FROM .500 IN TO 3.0 INCH. IT SHOULD BE NOTE THAT MAG PARTICLE INSP IS NOT A REQUIREMENT OF AIR FRAME MFG. (K)

CA070704012

REIMS  

PWA  

 

SEAL

FRACTURED

5/11/2007

F406

PT6A112

 

3022375

HYDRAULIC PUMP

(CAN) IN CRUISE, ENGINE OIL PRESSURE WAS SEEN TO FLUCTUATE AND SUBESQUENTLY DECREASE. OIL WAS SEEN ESCAPING FROM THE ENGINE NACELLE. THE ENGINE WAS SHUTDOWN IN FLIGHT. SUBSEQUENT INVESTIGATION REVEALED A FRACTURED HYDRAULIC PUMP PAD OIL SEAL. (TC NR 20070704012)

CA070704005

ROBSIN

LYC  

 

DOOR FRAME

CRACKED

6/27/2007

R22BETA

O320B2C

 

R2210151

PAX DOOR

(CAN) DURING VISUAL INSPECTION TO COMPLY WITH AWD 2005-16-05 LT DOOR ASSY WAS FOUND CRACKED. FUTHER INSPECTION OF THE TECH-TOOL DOOR AND FRAME REVEALED ADDITIONAL CRACKS. DOOR FOUND TO BE U/S AND REMOVED FROM A/C. (TC NR 20070704005)

CA070615002

ROBSIN

LYC  

 

DRIVE BELT

SEPARATED

6/6/2007

R22BETA

O360J2A

 

A1902

MAIN ROTOR

(CAN) BELTS WERE REPLACED AT 2200HR OVERHAUL AND AFTER 38 HRS IN SERVICE WERE FOUND SEPARATED IN A SECTION ABOUT 2 INCHES LONG. (TC NR 20070615002)

BAI71007

ROBSIN

LYC  

 

BELT

BROKEN

7/10/2007

R22BETAII

O360A1D

 

A1902

M/R DRIVE

MAIN ROTOR DRIVE BELTS SEPARATED IN FLIGHT CAUSING THE CLUTCH ACTUATOR TO RUN EXCESSIVELY. THE OVER-TRAVEL LIMIT-SWITCH LANYARD WAS SEVERED BY A PORTION OF THE BROKEN BELTS AND DID NOT PERFORM IT'S INTENDED FUNCTION. THE PIC HAD TO DISABLED THE CLUTCH ACTUATOR SYSTEM BY PULLING THE CLUTCH CIRCUIT BREAKER AND THEN AUTO ROTATED TO THE GROUND. THERE WAS NO ADDITIONAL DAMAGE TO THE AIRCRAFT OR INJURY TO OCCUPANTS AS A RESULT OF THE AUTOROTATION.

CA070622003

ROBSIN

LYC  

 

SHAFT

WORN

6/19/2007

R44RAVENII

IO540AE1A5

 

 

CLUTCH

(CAN) LOUD (BANG) HEARD DURING FLIGHT. CLUTCH SUSPECTED. REMOVED TO INSPECT. CLUTCH WAS TORN DOWN IN THE COMPONENT SHOP AND SHAFT WAS FOUND WORN BEYOND LIMITS. SPRAG WAS MOST LIKELY DRAGGING ON THE SHAFT. CLUTCH AND SHAFT ASSY BEING SENT BACK FOR WARRANTY. (TC NR 20070622003)

CA070629003

ROBSIN

LYC  

 

RESERVOIR

LEAKING

5/25/2007

R44RAVENII

IO540AE1A5

 

D2112

HYD SYSTEM

(CAN) DURING POST INSPECTION RUN UPS, IT WAS WITNESSED THE HYDRAULIC RESERVIOR WAS VENTING HYDRAULIC FLUID OUT OF THE VENT. NO DETERMINING FACTOR COULD BE FOUND, SO THE RESERVIOR WAS REPLACED AND NO FURTHER ISSUES WERE NOTED. (TC NR 20070629003)

CA070801006

SAAB

GE  

 

LIGHT

OVERHEATED

7/29/2007

340B

CT75A2

 

BR6303121

CABIN

(CAN) CABIN OVERHEAD FLOURESCENT LIGHTING FIXTURE OVERHEATED. BURNED OUT BULB FOUND AND CONTACTS IN FIXTURE THAT CONDUCT ELECTRICITY TO BULB FOUND LOOSE AND OVERHEATED, CAUSING PLASTIC PART OF ASSY TO OVERHEAT. PARTS REPLACED AND A/C RELEASED TO SERVICE WITHOUT ANY FURTHER INCIDENT. (TC NR 20070801006)

CA061117007

SAAB

GE  

 

PDU  

FAILED

11/2/2006

SF340A

CT75A2

 

A2042C

LT START RELAY

(CAN) WHEN GROUND POWER WAS ATTACHED TO THE AIRCRAFT THE LT ENGINE BEGAN AN UNCOMMANDED START SEQUENCE. THE FAULT WAS TRACED TO THE LT STARTER RELAY CONTACTS LOCATED IN THE LT POWER DISTRIBUTION UNIT (PDU). THE PDU WAS REPLACED AND THE AIRCRAFT OPERATED NORMALLY. (TC NR 20061117007)

CA070619007

SKRSKY

GE  

 

BOLT

LOOSE

6/11/2007

S61N

CT581401

 

 

FCU CONNECTION

(CAN) OCCURRENCE WHERE THE ENGINE SPEED CONTROL DISENGAGED FROM THE FUEL CONTROL UNIT, RESULTING IN AN IN-FLIGHT SHUTDOWN OF THE ENGINE. SUSPECTED CAUSE WAS A LOOSE SELF LOCKING BOLT, P/N NK4-4A, AND OR A WORN NON METALLIC LOCKING INSERT ON THE NK4-4A BOLT. IN ORDER TO PREVENT THIS FROM HAPPENING AGAIN, THE MAINTENANCE CREW HAVE BEEN REMINDED TO TAKE CARE WHEN INSTALLING THE SPEED CONTROL WHEN RE-USING THE NK4-4A BOLT TO ENSURE THAT THERE IS THREAD INTERFERENCE. MM, SA 4045-80, SECTION 20-00, PAGE 5, PARAGRAPH 9 (REUSE OF SELF LOCKING NUTS), SUB-PARAGRAPH C. STATES THAT ALL NUTS MUST BE CHECKED BEFORE RE-USE. THERE MUST BE THREAD INTERFERENCE, SUCH INTERFERENCE INDICATES THAT THE SELF LOCKING FEATURE IS WORKING. (ALTHOUGH THE STANDARD PRACTICES SECTION REFERS TO THE RE-USE OF NUTS ONLY. I BELIEVE THAT THE SAME REQUIREMENT APPLIES TO THE SELF LOCKING FEATURE OF THE NK4-4A BOLT.) (TC NR 20070619007)

CA070803004

SKRSKY

PWA  

 

OIL SYSTEM

LEAKING

6/1/2007

S76B

PT6B36

 

 

ENGINE

(CAN) ENGINE OIL TEMPERATURE WAS OBSERVED TO INCREASE IN FLIGHT AND THE PILOT ELECTED TO SHUT THE ENGINE DOWN. OIL WAS SUBSEQUENTLY SEEN LEAKING FROM THE ENGINE EXHAUST. MFG WILL INVESTIGATE THE EVENT AND ADVISE OF ROOT CAUSE ONCE DETERMINED. (TC NR 20070803004)

2007FA0000716

SKRSKY

TMECA

 

LAMP

BURNED OUT

8/1/2007

S76C

ARRIEL2S1

 

SB4580

SEARCH LIGHT

POSSIBLE MFG PARTS NOT TO SPECIFICATIONS. MFG OF ORIG UNKNOWN. (GENERIC) LESS THAN 7 FLT HOURS IAW LAMP (AVERAGE) FROM INSTALLATION TO REPLACEMENT. HAVE REPLACED AT LEAST 5 LAMPS IAW AIRCRAFT IN LESS THAN 30 FLIGHT HOURS EACH. NO CIRCUIT BREAKERS POPPING. TROUBLESHOOTING SHOWS NO DISCREPANCIES ON EITHER AIRCRAFT. NO MFG INFORMATION ON PARTS BOX OR ON THE PART. (K)

2007FA0000717

SKRSKY

TMECA

 

LAMP

BURNED OUT

8/1/2007

S76C

ARRIEL2S1

 

SB4580

LANDING LIGHT

POSSIBLE MFG PARTS NOT TO SPECIFICATIONS. MFG OF ORIGIN UNKNOWN. (GENERIC) LESS THAN 7 FLT HOURS PER LAMP (AVERAGE) FROM INSTALLATION TO REPLACEMENT. HAVE REPLACED AT LEAST 5 LAMPS PER AC IN LESS THAN 30 FLIGHT HOURS EACH. NO CIRCUIT BREAKERS POPPING. TROUBLESHOOTING SHOWS NO DISCREPANCIES ON EITHER AC. NO MFG INFO ON PARTS BOX OR ON THE PART COPY OF ORIGINAL CERTIFICATION ATTACHED. (K)

2007FA0000753

SNIAS

TMECA

 

LINE

LEAKING

7/24/2007

AS350B2

ARRIEL1D1

 

704A34412938

HYD SYSTEM

AC HAD HYDRAULIC LIGHT, PILOT PERFORMED A PRECAUTIONARY LANDING AT THE AIRPORT. UPON INSP FOUND HYDRAULIC LINE FROM PUMP TO MANIFOLD LEAKING AT THE BOTTOM OF THE SWEDGE FITTING. HYDRAULIC LINE WAS REPLACED WITH NEW LINE. HYDRAULIC SYSTEM WAS SERVICED, GROUND RUN, AND LEAK CHECK NORMAL. FLIGHT CONTROL CHECK NORMAL. AC WAS RETURNED TO SERVICE. (K)

WTU0702

SNIAS

TMECA

 

STARTER GEN

INOPERATIVE

8/28/2007

AS350B2

ARRIEL1D1

 

150SG122Q

ENGINE

WHILE CONDUCTING A ROUTINE PATROL AT NIGHT THE GENERATOR FAILED AND WOULD NOT RESET. ALL NON ESSENTIAL EQUIPMENT WAS SHUTOFF AND THE PILOT RETURNED TO BASE UTILIZING BATTERY BUSS POWER WITHOUT FURTHER INCIDENT.

CA070625005

SNIAS

TMECA

 

PUSH-PULL ROD

CHAFED

6/13/2007

AS350B2

ARRIEL1D1

 

21863753

T/R GEARBOX

(CAN) HEAT SHRINK WHICH PROTECTS THE TAIL ROTOR PUSH PULL TUBE AS IT GOES THRU BEARING P/N 359A27-1191-20 IS CHAFING PREMATURLY AT THE AFT MOST BEARING LOCATION ON THE TAILBOOM. IPC 67.20.10.00006.00 FIG. 3 (TC# NR 20070625005)

CA070608006

SNIAS

TMECA

SNIAS

STARFLEX

DAMAGED

6/6/2007

AS350B2

ARRIEL1D1

 

350A31190700

MAIN ROTOR HEAD

(CAN) WHILE WAITING FOR HIS CREW TO RETURN, THE PILOT NOTICED SOME BLACK SOOT AROUND ONE OF THE STARFLEX ARMS. FURTHER EXAMINATION REVEALED THAT THE STAINLESS STEEL BUSHING BONDED ON THE END OF THE STARFLEX ARM HAD COME LOOSE AND WAS FLOATING INSIDE THE SPHERICAL BEARING IN THE FREQUENCY ADAPTER. THE BUSHING WAS IN GOOD CONDITION THAT MORNING BEFORE THE FLIGHT AND NO UNUSUAL NOISES OR VIBRATIONS WERE DETECTED PRIOR TO DISCOVERING THE DAMAGED STARFLEX. THE PILOT AND CREW HAD TO BE FLOWN OUT OF THE BUSH WITH ANOTHER HELICOPTER. A NEW STARFLEX WAS INSTALLED ON SITE THE NEXT DAY WITH NO FURTHER ISSUES. (TC NR 20070608006)

WTU0701

SNIAS

TMECA

 

STARTER GEN

SEIZED

7/19/2007

AS350B2

ARRIEL1D1

 

150SG122Q

ENGINE

WHILE CONDUCTING A SEARCH OVER MOUNTAINOUS TERRIAN AT NIGHT UTILIZING AN SX-5 SEARCHLIGHT, TEN MINUTES INTO THE SEARCH LIGHT QUIT WORKING. APPROXIMATELY 30 SECONDS LATER THE GENERATOR FAIL LIGHT ILLUMINATED AND THE CREW SMELLED SMOKE IN THE COCKPIT. APPROXIMATELY 30 SECONDS LATER THE FIRE LIGHT ILLUMINATED. THE PILOT IMMEDIATELY EXCEUTED EMERGENCY PROCEDURES BY TURNING OFF THE GENERATOR AND LAND AS SOON AS PRACTICAL. AFTER THE PILOT LANDED AND SHUTDOWN THE AIRCRAFT THEY EXITED AND SAW SMOKE COMING OUT OF THE STARTER GENERATOR COOLING DUCT TUBE. THE CREW OPENED THE ENGINE COWLING AND THERE WAS NO FIRE BUT EVIDENCE THAT THERE MAY HAVE BEEN ONE INSIDE THE S/G. UPON REMOVAL THE S/G HAD A SHEARED SHAFT IT WAS SEIZED. AN INTERNAL FAILURE CAUSED THE S/G TO OVERHEAT TO A POINT OF FLASH FIRE THEN SEIZURE.

2007FA0000640

SWRNGN

GARRTT

 

SOLENOID VALVE

FAILED

7/2/2007

SA226T

TPE33110U

 

 

NLG STEERING

THE NOSE WHEEL STEERING WAS TESTED PRIOR TO FLIGHT, AD TESTED SATISFACTORY. AT AROUND 60 TO 70 KNOTS DURING THE TAKEOFF ROLL, THE AC STEERING FAILED IN A MANOR THAT RESULTED IN THE AC PULLING HARD TO THE LEFT. USING HARD RT BRAKE AND RT REVERSE THRUST THE AC WAS STOPPED BEFORE RUNNING OFF THE RUNWAY. WHEN THE SPEED LEVER WAS RETARDED THE STEERING , RE-ENGAGED, AS IT SHOULD HAVE, AND THE AC OPERATED NORMALLY.

2007FA0000731

SWRNGN

GARRTT

 

PIPE

ARCED

6/25/2007

SA226TC

TPE331*

 

2784187019

RT WING BLEED AI

IB OF RT NACELLE, BLEED AIR PIPE (PN 2784187019), CHAFED OR BURNED THROUGH THE ASBESTOS SLEEVE SURROUNDING THE STARTER RELAY WIRING, WHICH THEN ARCED A HOLE IN THE BLEED PIPE, WHICH THEN BURNED THE SHIELDING FROM THE STARTER RELAY WIRES, WHICH THEN ARCED A HOLE IN A HYDRAULIC LINE (PN 2781032403), RESULTING IN A FIRE.

CA061124005

SWRNGN

GARRTT

 

CHANNEL

CRACKED

11/21/2006

SA226TC

TPE33110UA

 

2736041001

TE FLAP

(CAN) DURING OVERHAUL OF THE RT FLAP ASSY, THE CENTER HINGE CHANNEL WAS REMOVED FOR REPLACEMENT AND WAS FOUND CRACKED BETWEEN (2) RIVET HOLES. THE CHANNEL HAS BEEN REPLACED. (TC NR 20061124005)

CA070112003

SWRNGN

GARRTT

 

WINDSHIELD

CRACKED

1/11/2007

SA226TC

TPE33110UA

 

2719442003

COCKPIT

(CAN) UPON LANDING THE FLIGHT CREW WITNESSED THE LT HEATED WINDSHIELD CRACK FROM THE LOWER RT CORNER TO THE UPPER CENTER PORTION OF THE WINDOW. THE LANDING WAS REPORTED AS NORMAL AND NO ABNORMAL INDICATIONS WERE NOTICED PRIOR TO FAILURE OF THE WINDOW. UPON INSPECTION BY MAINTENANCE, THE WINDOW WAS FOUND CORRECTLY INSTALLED AND TRIMMED TO FIT CORRECTLY. THE ATTACHING SCREWS WERE TORQUE CHECKED AND A FEW WERE FOUND SLIGHTLY UNDERTORQUED. IT IS UNLIKELY THIS CAUSED THE FAILURE AS THIS OPERATOR HAS HAD SEVERAL IN FLIGHT HEATED WINDSHIELD FAILURES WITHIN THE LAST 24 MONTHS. ANOTHER OPERATOR OPERATING SIMILAR AIRCRAFT IN THE PNR HAS REPORTED INCREASED FAILURES AS WELL OF THESE HEATED WINDSHIELDS. THE WINDSHIELD IS BEING REPLACED. (TC NR 20070112003)

CA070727008

SWRNGN

GARRTT

 

MASTER CYLINDER

FAULTED

7/17/2007

SA226TC

TPE33110UA

 

VI151000

BRAKES

(CAN) AIRCRAFT ABORTED TAKEOFF DUE TO A DRAGGING BRAKE. UPON MAINTENANCE INSPECTION THE RT BRAKE MASTER CYLINDERS WERE FOUND AT FAULT. BRAKE PRESSURE COULD NOT BE RELEASED BY THE AFFECTED MASTER CYLINDERS. BOTH NR 2 AND NR 4 BRAKE MASTER CYLINDERS WERE REPLACED. NR 2 CYLINDER P/N V-1000 S/N 3187 TSO - 4382.9, NR 4 CYLINDER P/N VI-15-1000 S/N 13008 TSO- 7753.3. (TC NR 20070727008)

CA070720005

SWRNGN

GARRTT

 

ACTUATOR

MALFUNCTIONED

7/19/2007

SA226TC

TPE33110UA

 

 

PITCH TRIM

(CAN) AFTER FLAP RETRACTION, FLIGHT CREW DISCOVERED THAT THEY HAD NO CONTROL OF PITCH TRIM USING PRIMARY OR SECONDARY CIRCUITS. AFTER DISCUSSION WITH MAINTENANCE, FLIGHT CONTINUED TO MAINTENANCE BASE WHERE MAINTENANCE REPLACED TRIM ACTUATOR. (TC NR 20070720005)

CA070615005

SWRNGN

GARRTT

 

AUDIO CONTROL

STICKING

6/13/2007

SA227AC

TPE3311

 

M1035CHKFJLJ2

 

(CAN) BUTTONS HAVE TO BE PRESSED NUMEROUS TIMES BEFORE THEY ENGAGE, REPLACED UNIT. (TC NR 20070615005)

CA070606002

SWRNGN

GARRTT

 

LINE

CRACKED

6/2/2007

SA227AC

TPE33111U

 

2781032261

HYD SYSTEM

(CAN) HYD LEAK IN RT WHEEL WELL. FOUND LINE CHAFED, LINE REPLACED AND AIRCRAFT RETURNED TO SERVICE AFTER SUCCESSFUL GEAR SWINGS CARRIED OUT. (TC NR 20070606002)

CA061018011

SWRNGN

GARRTT

 

CABLE

BROKEN

10/18/2006

SA227AC

TPE33111U

 

3219012123

POWER LEVER

(CAN) RT POWER LEVER CABLE WAS DISCOVERED BROKEN 1 FOOT FROM POWER LEVER ATTACH POINT (TC NR 20061018011).

CA061018012

SWRNGN

GARRTT

 

WINDSHIELD

FAILED

10/15/2006

SA227AC

TPE33111U

 

92063H0421

COCKPIT

(CAN) AIRCRAFT WAS IN CRUISE FLIGHT WHEN THE RT WINDSHIELD SHATTERED, OUTER PANE. THE ELT WENT OFF AND HAD TO BE RESET AT THE SAME TIME. REPORTS OF ARCING ON INSIDE OF WINDSHIELD FROM (P) STATIC BEFORE OUTER PANE CRACKED. (TC NR 20061018012)

CA070621001

UROCOP

TMECA

UROCOP

BUSHING

FAILED

6/21/2007

EC120B

ARRIU2F

 

 

SCISSOR LINK

(CAN) FACTORY NON- FIELD REPLACEABLE BUSHING BOND FAILED IN THE SCISSOR LINK, BROKE FREE AND WORE INTO THE SISSOR LINK. EXCESSIVE PLAY AND "SMOKE" WAS EVIDENT. (TC NR 20070621001)

CA070622007

UROCOP

TMECA

 

SCISSOR LINK

FAILED

6/19/2007

EC120B

ARRIU2F

 

C623A2005103

MAIN ROTOR

(CAN) (1) OF (4) BONDED BUSHINGS FAILED, RESULTING EXCESSIVE PLAY/SMOKING. BUSHING CONTINUED TO WEAR INTO SCISSOR LINK UNTIL CAUGHT AT FIRST 100 HOUR INSPECTION (SINCE NEW). (TC NR 20070622007)

2007FA0000638

UROCOP

PWA  

 

BLADES

DAMAGED

6/25/2007

EC135P1

PW206B

 

 

ENGINE

DURING FLIGHT, A LOUD BANG WAS HEARD AND THEN ALL ENGINE INSTRUMENTS SHOWED AN INDICATION OF A TOTAL ENGINE FAILURE. THE ENGINE WAS SECURED AND A SINGLE ENGINE LANDING WAS INITIATED WITHOUT INCIDENT. UPON INSPECTION, IT WAS NOTICED THAT THE EXHAUST AREA OF THE ENGINE, THERE WERE PT ROTOR BLADES MISSING OR DAMAGED. THE ENGINE WILL BE SENT BACK TO THE MFG FOR EVALUATION. (K)

 

END OF REPORTS