44
CONTENTS | ARTICLES | AIRWORTHINESS | REGULARS
Service difficulty reports
7 August – 17 September 2013
Note: Similar occurrence figures not included in this edition
ABOVE 5700kg
Airbus A320-232 Aerodynamic fairing – tail
cone damaged. SDR 510017442
Aircraft tail cone suffered extensive damage
when contacted by the wingtip of another aircraft.
Investigation continuing.
Airbus A320-232 APU oil cooler leaking.
SDR 510017590
APU oil cooler leaking. Investigation continuing.
P/No: 1604941. TSN: 12982 hours/11145 cycles
Airbus A320-232 Battery unserviceable.
SDR 510017620
Light electrical smell. Investigation found spare
battery in galley box arcing. Investigation continuing.
P/No: BIM81XX1K9KGX.
Airbus A320-232 Control column section –
connector loose. SDR 510017480
First officer's sidestick binding. Investigation found
binding caused by a loose wiring loom which had
been stowed following removal of the electronic flight
bag (EFB).
Airbus A320-232 Emergency locator beacon –
ELT AD requirement. SDR 510017523
ELT battery wire damaged. Found during inspection
iaw AD CF-2013-25 and Honeywell alert bulletin
1152682-23-A22 Rev 01. P/No: 11526823.
Airbus A330-202 Air distribution fan –
recirculation fan faulty. SDR 510017472
Smell/smoke in cockpit and cabin. Investigation found
RH recirculation fan faulty. Investigation continuing.
P/No: VR410004. TSN: 981 hours. TSO: 981 hours
Airbus A330-243 Aircraft fuel distribution system –
actuator faulty. SDR 510017543
Inner fuel tank inlet valve actuator (603QL1) faulty.
P/No: D97C00654.
Airbus A380-842 Landing gear position and
warning system – proximity sensor failed.
SDR 510017608
LH body landing gear door proximity sensor
unserviceable. Found during inspection iaw SB
A380-92-8059.
Air Tractor AT802A Vertical stabiliser attach
fittings – fitting corroded. SDR 510017592
Vertical stabiliser front spar attachment fitting plate
corroded. P/No: 305111. TSN: 1,987 hours/84 months
ATR ATR72212A Brake anti-skid section –
module failed. SDR 510017517
Anti-skid module failed. Module was leaking between
housing and adapter. Module had been installed the
previous day. P/No: 397393.
ATR ATR72212A Crew station equipment
system – spring broken. SDR 510017433
Captain's seat fore/aft lock spring broken. Two similar
defects. P/No: 1A5270016. TSN: 4351 hours/4190
cycles/28 months
BAC 146-100 Hydraulic system main – hose holed.
SDR 510017513
Yellow hydraulic system hydraulic pressure hose
to rudder actuator split. Loss of hydraulic fluid.
P/No: SA7670006135.
BAC 146-300 Engine temperature indicating
systems – socket loose. SDR 510017460
No. 2 engine TGT wiring sockets P/Nos. S1034-001 and
S1034-002 loose. Sockets located at wing/fuselage
production zone 285-02-00. Investigation also found
incorrect contact socket on plug RB wire 3EF132.
Boeing 717-200 Cabin heater failed. SDR 510017431
Burning smell in cabin. Investigation found forward cargo
heater circuit breakers tripped. CBs reset but tripped
again. Cargo heater declared u/s.
Boeing 717-200 Trailing edge flaps – hinge
unserviceable. SDR 510017459
No. 4 flap idler hinge outboard lower stud
P/No: 4919290-507 sheared. Investigation also
found the stud inboard bore had crack indications
and the outboard bore was damaged. Significant
exfoliation corrosion also found to the rear spar under
the hinge position. P/No: 5913528507.
TSN: 25882 hours/17705 cycles
FLIGHT SAFETY AUSTRALIA
Issue 94 September–October 2013
Boeing 737-3YO Fuselage plates/skin –
skin cracked. SDR 510017439
Fuselage skin cracked in area located at Stn 940
stringer 24L. Crack length approximately 76.2mm (3in).
Crack was beyond limits.
Boeing 737-838 APU oil system – oil cooler
contaminated. SDR 510017426
APU oil cooler fins heavily contaminated causing high
oil temperatures. P/No: 1605642.
Boeing 737-838 ATC transponder system –
switch faulty. SDR 510017462
ATC No. 2 upper antenna switch (S942) faulty.
Found during transponder testing iaw AD/Rad/47.
P/No: 402167.
Boeing 737-838 Fuel shutoff valve – auto shutoff
system suspect faulty. SDR 510017482
RH centre fuel tank boost pump auto shutoff system
intermittent in operation. Found during inspection iaw
AD 2008-10-10.
Boeing 737-838 Fuel wiring – wire faulty.
SDR 510017629
Centre RH fuel tank boost pump wires W6210-0215-20
and W6210-0214-20 failed voltage check. Investigation
found wires transposed at terminals X1 and X2 of centre
tank right relay R963. Found during inspection iaw
AD N37-028-0065.
45
Boeing 737-8FE APU bleed valve unserviceable.
SDR 510017562
APU bleed valve assembly u/s. During bleed checks
following valve replacement a large leak was found
from the ‘Y’ duct between the bleed valve and surge
control valve. Further investigation found two of four
bolts P/No: MS9557-08 attaching the duct to the
compressor scroll were missing and the ‘O’ ring seal
P/No: S8990-153 was blown out. P/No: 3292142.
TSN: 9,865 hours/13294 cycles
Boeing 737-8FE Outside air temperature indicator/
sensor – probe unserviceable. SDR 510017467
Total air temperature (TAT) probe damaged by contact
with aero bridge.
Boeing 737-8FE Passenger/crew door seal FOD.
SDR 510017458
Loud air noises from R2 door during flight. Two catering
seals/ties found on the lower forward door sill. Seal not
damaged or distorted and the noise ceased following
removal of the FOD. Cabin pressurisation not affected.
Boeing 737-8Q8 Hydraulic power wiring –
wire short circuit. SDR 510017494
Standby hydraulic pump wiring bundle W8538
chafing and short circuiting on fairing. Investigation
found wiring loom slack. P/No: W8538.
Boeing 737-838 Wheel bolt sheared.
SDR 510017527
LH outboard main wheel tie bolt (2off) sheared.
One similar defect. P/No: 277A6000204.
TSN: 10707 hours TSO: 551 hours
Boeing 767-338ER APU cowlings/containment –
APU leaking. SDR 510017502
Oil smell in cabin. Initial investigation found oil wetting in
the APU bleed air supply duct. Investigation continuing.
Boeing 767-338ER Fuel boost pump –
pressure switch failed test. SDR 510017471
LH fuel jettison pump pressure switch failed test.
Found during inspection iaw AD 2008-11-01. Two similar
defects. P/No: 21C1321.
46
CONTENTS | ARTICLES | AIRWORTHINESS | REGULARS
Service difficulty reports
Bombardier DHC8-315 Hydraulic pressure regulator
main - regulator faulty. SDR 510017479
No2 hydraulic system caution light illuminated then
extinguished before illuminating again. Suspect faulty
hydraulic system. Investigation found a faulty rudder
dual pressure regulator.
Bombardier DHC8-315 Landing gear retract/
extension system loose connection. SDR 510017473
Landing gear failed to extend and landing gear doors
remained closed. After conducting a go-around gear
eventually extended normally. Loose wire from inhibit
switch to the landing gear solenoid valve.
Bombardier DHC8-315 Pitot/static anti-ice system
suspect faulty. SDR 510017601
Investigation found pitot/static heat system circuit breaker
popped. CB reset and system tested serviceable.
Bombardier DHC8-402 Aileron control system
cable worn. SDR 510017561
LH and RH aileron cables worn beyond limits.
P/No: 82742407001. TSN: 15657 hours/17890 cycles
No.1 Multi-function display unit suspect faulty.
Investigation continuing.
Bombardier DHC8-402 Door warning system
washer worn. SDR 510017612
Forward baggage door warning light. Investigation
found warning sensor bracket washers worn,
causing door warning system to be out of adjustment.
P/No: AN960D416L.
Bombardier DHC8-402 Pneumatic distribution
system HPSOV faulty. SDR 510017575
Engine warning light illuminated. Initial investigation
could not rectify fault. RH High-pressure shutoff valve
Boeing 777-3ZGER Hydraulic system hose cracked
(HPSOV) faulty. P/No: 2005100618.
and leaking. SDR 510017558
Convair 340 Engine emergency shutdown system –
Hydraulic hose to elevator PCU leaking. Hose has a
switch corroded. SDR 510017526
Kevlar inner lining which cracks/ruptures allowing fluid
LH engine emergency shutdown switch plunger shaft
leakage. 1 similar defect. P/No: AS4568J0444SS.
retaining ring corroded, with ring eventually failing.
Bombardier DHC8-102 Engine oil cooler – oil cooler
Found during inspection iaw SL 580-76-001. P/No: 8PB1.
leaking. SDR 510017419
Fokker F27MK50 Passenger seats – cross members
RH engine oil cooler leaking. Investigation found one
cracked. SDR 510017560
of the inlet fitting helicoils had dislodged, allowing oil to
Passenger seat aisle cross members cracked on seats
bypass and leak. Cooler was an overhauled item that
2DF and 8DF. Found during inspection iaw AD/Seat/
had failed on the first flight after fitment. One similar
16 A1 and CSB 312/912-02 Rev 1.
defect. P/No: 28E997. TSO: 1 hour
Fokker F27MK50 Power lever stiff. SDR 510017595
Bombardier DHC8-311 Landing gear retraction
RH power lever stiff in operation. Investigation found
system suspect faulty. SDR 510017420
Nose landing gear failed to retract. Investigation found no a build-up of inhibitor on the cables and fairlead
definitive cause for the defect and further retraction tests pressure seals. Power levers still difficult to move.
Investigation continuing.
could not fault the system.
Fokker F28 MK0100 AC power distribution system
Bombardier DHC8-314 Emergency equipment
bracket faulty. SDR 510017451
system – ditching dam inadvertent operation.
During replacement of a u/s transformer rectifier unit
SDR 510017469
(TRU) the circuit breaker tripped and earth wire insulation
RH ditching dam deployed and was slightly inflated
started to burn. Investigation found faulty bonding on
during flight. Inflation line open to cabin pressure and
the TRU attachment brackets after painting.
rupture disc burst. P/No: 4MA102510.
Boeing 777-3ZGER Exterior lighting – light
unserviceable. SDR 510017530
Tail light burnt out. Suspect internal arcing.
Investigation continuing. P/No: 3024813.
TSN: 19724 hours/1,625 cycles
FLIGHT SAFETY AUSTRALIA
Issue 94 September–October 2013
Fokker F28 MK0100 brake disintegrated.
SDR 510017594
LH main landing gear No.1 wheel locked due to
disintegrated brake discs. Investigation continuing.
Fokker F28 MK0100 Potable water system –
pipe failed. SDR 510017463
Galley potable water pipe ruptured in area before the
galley stop tap. Water contamination of galley, cockpit,
cabin and numerous electrical components after the
entire contents of the tank emptied because the water
could not be turned off.
Fokker F28 MK070 Brake damaged. SDR 510017421
LH brake reported to require more pressure than the
RH brake. FOD of LH main landing gear outboard
brake. Bolt from a wheel disc drive channel key wedged
between rotors and stators.
IAI 1124 Elevator control system cable worn.
SDR 510017499
Forward elevator transition cable worn and tension low.
P/No: 503028555.
Saab SF340B Airfoil de-ice boot ruptured.
SDR 510017430
RH horizontal stabiliser de-ice boot torn.
Tear approx. 300mm (11.8in) long. Two similar defects.
P/No: P29S7D514126.
Saab SF340B Landing gear wire worn and
damaged. SDR 510017568
Landing gear selector valve wire worn through and short
circuiting on hydraulic pipe.
47
AIRCRAFT BELOW 5700KG
Alpha Aviation R2160 Fuselage plates/skin
cracked. SDR 510017455
RH lower fuselage skin cracked in area located
approx. 1270mm (50in) aft of the firewall and 355.6mm
(14in) right of the centreline. Evidence of oilcanning.
P/No: 212328490. TSN: 3178 hours
Avions Pierre Robin R2160 Wing spar cap
corroded. SDR 510017566
RH wing upper and lower spar caps P/Nos: 6057122001,
6057123001 and LH wing lower spar cap P/No: 60-57124-001 had heavy exfoliation corrosion. Numerous
other areas of spar caps and doublers also corroded.
Found during inspection iaw AD/Robin/32. TSN: 3,542
hours/183 months
48
CONTENTS | ARTICLES | AIRWORTHINESS | REGULARS
Service difficulty reports
Britton Norman BN2A20 Wing spar cap cracked.
SDR 510017418
LH and RH wing spar caps cracked. Found during
inspection iaw AD/BN-2/62. One similar defect.
Britton Norman BN2A21 Main landing gear strut/
axle/truck corroded and leaking. SDR 510017557
LH main landing gear oleo strut leaking. Strut badly
corroded internally with the ‘O’ ring land partially
corroded away. The ‘O’ ring was also found to be a
non-OEM seal.
Cessna 172N Engine air intake system arm worn.
SDR 510017422
Carburettor heat box valve arm worn and valve partly
separated from shaft.
Britton Norman BN2B20 Nacelle/pylon miso
structure angle cracked. SDR 510017581
LH main landing gear nacelle lower aft bracket angle
cracked. Found during inspection iaw AD/BN2/63.
Three similar defects. P/No: NB201909.
TSN: 13719 hours
Cessna 172N Brake disc corroded. SDR 510017425
RH main landing gear brake disc corroded.
Cessna 172N Engine mount section – mount worn.
SDR 510017424
Engine mount rear cross tube worn due to mixture
cable rubbing.
Cessna 172N Landing gear attach fittings – loose
rivets. SDR 510017423
Nose landing gear lower support fitting rivets loose and
working. Firewall slightly buckled.
Cessna 172RG Elevator control system – bellcrank
corroded. SDR 510017598
Elevator bellcrank corroded in area where stop bolt
contacts. Aircraft stored outside in a coastal environment.
P/No: 05341221. TSN: 6631 hours
Cessna 177B Nose landing gear strut/axle – oleo
strut unserviceable. SDR 510017571
Nose landing gear strut u/s. Unapproved repairs had
been carried out. Investigation found unusual marks on
tube, nil oil and approximately 51 spot weld repairs.
P/No: 1743000201. TSN: 3,232 hours
Cessna 208B Power lever – condition lever
fractured. SDR 510017528
Engine fuel condition lever fractured through rudder
control lock operating rod attachment bolt hole.
P/No: C2995140101. TSN: 12443 hours
Cessna 208 Landing gear position and warning
system – proximity switch failed. SDR 510017515
RH main landing gear proximity switch wire separated.
Salt water entering switch and causing corrosion. Aircraft
equipped with floats. P/No: 5801HAMLIN59135020.
FLIGHT SAFETY AUSTRALIA
Issue 94 September–October 2013
Cessna 402C Landing gear position and warning
system – switches unserviceable. SDR 510017511
Landing gear hydraulic pressure switch P/Nos 991028710
and LH uplock switch P/No: 602EN556B both u/s.
The failure of the switches prevented the hydraulic
system from switching off following gear retraction.
This in turn allowed the hydraulic pump to keep
operating and raise the temperature of the hydraulic
fluid, eventually causing the plastic sight tube on the
reservoir to melt and allow loss of hydraulic fluid.
Cessna 404 Wing spar web debonded.
SDR 510017438
RH wing rear spar web had a minor debond. Found
during ultrasonic inspection iaw AD/Cessna400/103
and AD/Gen/86 Req4.
Gippsland Aeronautics GA200C Wing spar caps
cracked. SDR 510017450
LH and RH wing lower spar caps cracked from WS 0.00
to WS 2.50 in area of attachment to fuselage. Crack
lengths approximately 50.8mm to 76.2mm (2in to 3in).
Found during inspection iaw SB GA200-2011-06 issue2.
P/No: GA2005710025.
49
Pilatus PC12 Aircraft fuel distribution system –
pipe unserviceable. SDR 510017607
Fuel feed pipe leaking in area of RH undercarriage.
Lower anti-collision wire LT8B18 rubbing and arcing on
fuel pipe. P/No: 5282412173
Gippsland Aeronautics GA8 Fuselage stabiliser
attach fittings - doubler cracked. SDR 510017428
RH horizontal stabiliser attachment fitting skin doubler
cracked. P/No: GA8538021310. TSN: 7,045 hours
Kavanagh B400 Balloon load frame cracked.
SDR 510017466
Balloon load frame cracked adjacent to previous repair.
P/No: LF148. TSN: 1,707 hours TSO: 1,707 hours
Pilatus PC12 Trailing edge flap control system
FCWU faulty. SDR 510017591
Replacement flap control and warning unit (FCWU)
faulty due to voltage sensitivity that resulted in erroneous
warnings when supply voltage dropped below 25 volts.
P/No: 9787320016
50
CONTENTS | ARTICLES | AIRWORTHINESS | REGULARS
Service difficulty reports
Swearingen SA227DC Wheel seal unserviceable.
SDR 510017461
Nose wheel bearing seal u/s. P/No: 13600LA.
TSN: 240 hours/307 cycles TSO: 240 hours/307 cycles
Piper PA28140 Control column section shaft
corroded. SDR 510017520
Pilot's control column shaft universal joint corroded
and seized.
COMPONENTS
Simmonds Precision Products Inc. 10056000001
indicator incorrectly marked. SDR 510017478
Fuel quantity repeater indicator incorrectly labelled.
Non-original equipment label made and stuck over
the original label, changing the part number from
10027000001 to 10056000001. No documentation for
the modification provided.
Piper PA31350 Elevator spar/rib – spar cracked.
SDR 510017507
RH elevator spar cracked at trim tab attachment.
P/No: 40076000. TSN: 16333 hours
Swearingen SA227DC GPS antenna
unserviceable. SDR 510017488
GPS antenna sealant deteriorated and gasket missing.
Antenna base severely corroded with minor
surface corrosion on airframe. P/No: 071015450200.
TSN: 9,694 hours/7,105 cycles/110 months
PISTON
Continental TSIO520VB Exhaust turbocharger seal
leaking. SDR 510017486
RH turbocharger leaking. Rear oil seal had failed.
Turbocharger had just been fitted and engine was being
test run.
FLIGHT SAFETY AUSTRALIA
Issue 94 September–October 2013
Continental TSIO520N Reciprocating engine
cylinder cracked and leaking. SDR 510017599
RH engine No. 5 cylinder cracked through induction
port and spark plug hole. LH engine cylinder similarly
cracked. Engines are fitted with ECI phase 3 nickel
barrel cylinders. P/No: AEC631397N714B.
TSN: 568 hours/26 months
51
Hartzell HCF2YR1 Propeller governor
unserviceable. SDR 510017613
Propeller governor u/s. Top cover cracked and separating
at bottom of lever housing. Investigation continuing.
P/No: C210776A. TSN: 8829 hours TSO: 98 hours
McCauley 3AF32C505 Propeller blade bearing
cracked and corroded. SDR 510017615
Propeller blade bearings dry and worn due to grease
leakage and water ingress. Remaining grease dried out.
Outer bearing also cracked. P/No: C5270.
TSO: 1,694 hours
McCauley 3FF32C501 Propeller spinner and
bulkhead unserviceable. SDR 510017617
Propeller spinner and bulkhead worn and damaged.
Mounting holes elongated.
ROTORCRAFT
Lycoming IO540K1A5 Fuel control/reciprocating
engines FCU leaking. SDR 510017565
Fuel control unit (FCU) leaking from area of throttle
control. Throttle control had sideways play.
FCU had been overhauled approx. 254 hours earlier.
P/No: 252427312. TSO: 254 hours/6 months
Agusta Bell A109E Ice and rain protection wiring
splice damaged. SDR 510017602
No. 2 pitot heater disconnect wiring splice damaged.
Splice was tightly wrapped in the centre of a wiring
loom allowing heat build-up that caused its plastic
cover to soften, distort and create an open circuit.
Lycoming IO540E1B5 Reciprocating engine
internal oil filter separated. SDR 510017583
LH engine oil filter threaded tube broke away from
adapter and filter separated.
Agusta Westland AW139 Tail rotor control
system - tube cracked. SDR 510017534
Tail rotor pedal assembly tubes (4off) cracked.
Found during inspection iaw BT 139-302.
P/No: M01501M17245. TSN: 1,001 hours
Bell 407 AC generator alternator PMA
unserviceable. SDR 510017519
Jabiru JABIRU2200B Reciprocating engine cylinder Engine-driven permanent magnet alternator (PMA)
piston damaged. SDR 510017489
drive sheared due to failed bearing.
No.1 cylinder piston destroyed and connecting rod bent. P/No: 90490052. TSN: 650 hours
Exhaust valve misaligned. Suspect caused by failure of,
Bell 429 Cabin cooling system fan unserviceable.
or incorrectly fitted, piston pin circlip.
SDR 510017614
PROPELLER
Air-conditioning system condenser fan u/s. Investigation
found wear in bushing preventing drive between motor
Hamilton Standard 14SF7 Propeller blade bearing
and fan and allowing fan to freewheel and tips to
damaged. SDR 510017573
rub. Found during inspection iaw Air Comm SL 263.
LH propeller No. 3 blade bearing damaged, allowing
P/No: S6063EC1. TSN: 467 hours
oil loss.
52
CONTENTS | ARTICLES | AIRWORTHINESS | REGULARS
Service difficulty reports
Eurocopter AS332L Main rotor gearbox filler cap
loose and leaking. SDR 510017429
Main gearbox oil filler cap loose and leaking
and ‘O’ ring dislodged. Loss of gearbox oil.
P/No: 706A34542007.
Eurocopter AS365N Fuselage window frame
cracked. SDR 510017484
LH canopy frame cracked.
Eurocopter AS350B2 Main rotor gearbox thrust
plate incorrect fit. SDR 510017622
Main rotor gearbox epicyclic reduction gear thrust
washer plate incorrectly installed. P/No: 350A32010010.
Robinson R44 Engine noise suppressor muffler
collapsed. SDR 510017626
Exhaust muffler collapsed at tailpipe attachment.
Found during inspection iaw AWB-78-001.
P/No: C16932. TSN: 664 hours
Robinson R44 Engine/transmission coupling
limit switch failed. SDR 510017529
Engine to transmission clutch actuator shaft broken.
Investigation suspects the retraction limit switch
failed allowing the actuator to run on. TSN: 1,651
hours/72 months
FLIGHT SAFETY AUSTRALIA
Issue 94 September–October 2013
Robinson R44 Main landing gear elbow cracked
and corroded. SDR 510017441
Landing gear aft cross tube elbow corroded.
While removing the corrosion, a crack was found.
Crack approx. 50.8mm (2in) long. Further inspection
found another crack in the opposite elbow
approximately 12.7mm (0.5in) long. P/No: C2401.
TSN: 1,079 hours
53
PWA PT6A41 Turbine engine metal contamination.
SDR 510017621
LH engine oil pressure fluctuating followed by surge
and shutdown. Initial investigation found metal in oil
filter and on chip detector. P/No: PT6A41.
TURBINE ENGINES
Allison 250C20B Turbine governor drive shaft
failed. SDR 510017606
Power turbine governor input shaft failed. Drive spline
worn causing erroneous signals to FCU.
Garrett TFE7312 Turbine engine compressor
carbon seal leaking. SDR 510017497
RH engine No. 3 carbon seal leaking. Pressurisation
system also found to be faulty because bleed valve
control box relay had loose contacts. P/No: 30604581.
PWA PW121 Turbine engine oil pump
unserviceable. SDR 510017505
RH engine oil pump idler gear shaft sheared.
Metal contamination of oil system.
PWA PT6A67B Turbine engine reduction gearbox
metal contamination. SDR 510017554
Reduction gearbox chip detector light illuminated.
Sliver of metal on the detector. Suspect metal might
have come from a planet gear.
Rolls Royce Trent97284 Turbine engine
compressor coupling worn. SDR 510017447
No. 3 engine IP coupling splines worn beyond
limits. Found during boroscope inspection iaw
RB211-72-AG329.
TO REPORT URGENT DEFECTS
CALL: 131
757
FAX:
02 6217 1920
or contact your local CASA Airworthiness Inspector [freepost]
Service Difficulty Reports, Reply Paid 2005, CASA, Canberra, ACT 2601
Online: www.casa.gov.au/airworth/sdr/