SERVICE DIFFICULTY REPORTS AIRWORTHINESS PULL-OUT SECTION
SELECTED SERVICE DIFFICULTY
REPORTS MAY-JUNE 2007
AIRCRAFT ABOVE 5700 KG
Airbus A330201 Hydraulic system pipe leaking.
Ref 510004637
Hydraulic pipe ‘B’ nut leaking at pipe flex line
located just aft of pitch trim actuator.
Airbus A330303 Escape slide faulty. Ref 510004470
Door 1L slide partially unpacked when door
opened. Investigation found that door 1L was
disarmed but the disarming lever was jammed
half way between ‘Arm’ and ‘Disarm’ positions.
The door was opened and the door arming
mechanism was found out of sync. The aft
slider assembly had engaged the girt bar but the
forward slider assembly had failed to engage
the girt bar. After removing the girt bar from the
slider assembly it was discovered that due to
the partial arming defect the slide has become
partially unpacked.
Beech 1900D Elevator control horn loose
rivets. Ref 510004564
Elevator control horn rivets loose and working.
P/No: 10161001914. TSN: 17,499 hours/16,869
cycles.
Boeing 717200 Flight compartment windshield
bird strike. Ref 510004509
Birdstrike on centre windshield during takeoff.
Boeing 7272J4 Main wheel damaged. Ref 510004721 (photo below)
No. 1 main wheel rim section separated from
hub. Tyre maintained pressure. Broken section
of wheel found on taxiway. P/No: 31414. TSO: 478 hours/177 cycles. (2 similar occurrences)
Boeing 737476 Autopilot system force limiter
faulty. Ref 510004678
Autopilot ‘B’ disengaged. Unable to engage
autopilot ‘A’. Investigation found a faulty aileron
force limiter. P/No: R1053M182. (2 similar occurrences)
Boeing 737476 Fuselage skin cracked. Ref 510004518
Fuselage skin located at Stn 950 stringer 17R
cracked at forward lower corner of door 2R
cutout. Crack length approximately 50.8 mm
running diagonally from the cutout radius edge in
a forward and downward direction approximately
45 degrees to the vertical plane.
(7 similar occurrences)
Boeing 737476 Galley oven failed. Ref 510004631
Forward galley oven C206 smoking. Investigation
continuing. P/No: GENM2585015. TSN: 33,764
hours/13,018 cycles. (13 similar occurrences)
Boeing 737476 Generator CSD failed. Ref 510004463
No. 1 engine generator Constant Speed Drive
(CSD) failed due to oil loss. P/No: 735511A. TSN:
29,872 hours. TSO: 11,657 hours. (7 similar occurrences)
Boeing 737476 Hydraulic system pipe cracked.
Ref 510004701
Hydraulic system ‘A’ pressure return line from LH
engine cracked and leaking. Pipe is located on
inboard side of wheel well adjacent to LH main
landing gear forward trunnion.
P/No: 650268093131. (5 similar occurrences)
Boeing 7374L7 Spoiler hinge broken. Ref 510004480
No. 4 ground spoiler hinge broken at outboard
actuator. P/No: 654645262A. TSN: 42,688 hours.
TSO: 42,688 hours. (1 similar occurrences)
Boeing 73776N Horizontal stabiliser skin
cracked. Ref 510004645
RH horizontal stabiliser lower skin cracked.
(32 similar occurrences)
Boeing 7377Q8 Flight management computer
software failed. Ref 510004639
Dual Flight Management Computer (FMC) failure.
Software problem. (5 similar occurrences)
Boeing 7377Q8 Public address/entertainment
system SEB faulty. Ref 510004502
Inflight entertainment system seat electronic
box (SEB) located at seat row 3ABC smoking.
Investigation found the tantalum capacitor C14
burnt. P/No: 3042865102. (2 similar occurrences)
Boeing 737838 Airconditioning pack diffuser
door missing. Ref 510004733
RH airconditioning pack diffuser door lost in
flight. P/No: 22156283.
Boeing 737838 Air intake anti-ice system valve
faulty. Ref 510004545
No. 1 engine inlet cowl thermal anti-ice valve
faulty. P/No: 32156183. TSN: 16,037 hours. TSO:
16,037 hours. (4 similar occurrences)
Boeing 737838 Brake pad separated. Ref 510004689
LH outboard brake pads separated and jammed
in brake keyway. Two heat shields damaged.
Investigation found two complete sections of
pad broken away with no evidence of damage to
axle or other parts of main landing gear.
P/No: 26123121. TSN: 5,373 hours.
Boeing 737838 Brake seized. Ref 510004730
RH outboard brake assembly seized. Brake
disintegrating. P/No: 26123121. TSN: 8,668
hours. TSO: 1,952 hours. (4 similar occurrences)
Boeing 737838 Central display DEU failed. Ref 510004613
Display Electronic Unit (DEU) failed.
P/No: 4081600930. (2 similar occurrences)
Boeing 737838 Flight compartment windshield
cracked. Ref 510004550
First Officer’s No. 2 windscreen cracked along
bottom edge. P/No: 141A481016. TSN: 500,913
hours. TSO: 500,913 hours. (9 similar occurrences)
Boeing 737838 Hydraulic system spoiler return
line leaking. Ref 510004482
Hydraulic leak at RH wing No. 9 trailing edge
spoiler return line. Investigation also found the
‘B’ system reservoir electric pump supply line
loose at elbow connection located below tank at
the forward bulkhead. (2 similar occurrences)
Boeing 737838 IDG line filter contam-metal.
Ref 510004484
No. 2 engine Integrated Drive Generator (IDG)
line filter contaminated with metal. P/No: 761574B.
(2 similar occurrences)
Boeing 737838 Landing gear selector valve
sticking. Ref 510004546
Landing gear selector lever stuck. Selector valve
P/No: 1FA01134-2 and restrictor valve P/No:
9R3806 replaced. Investigation continuing. P/No: 1FA011342.
Boeing 737838 Rudder trim actuator failed. Ref 510004514
Stabiliser trim electric actuator failed.
P/No: 6355B000103. (1 similar occurrences)
Boeing 737838 Stabiliser trim actuator failed.
Ref 510004634
Horizontal stabiliser trim actuator failed.
Investigation continuing. P/No: 6355B000103.
TSN: 14,326 hours. TSO: 14,326 hours. (9 similar
occurrences)
Boeing 7378BK Drag control system cable
broken. Ref 510004560
Ground spoiler interlock cable broken.
(10 similar occurrences)
Boeing 7378BK Passenger seat saddle
cracked. Ref 510004494
Passenger seat outboard rear saddle assembly
cracked on both sides of the rear weld. Crack
length approximately 3.175 mm. Seat located at
RH row 29. (13 similar occurrences)
Boeing 7378FE Air data inertial reference unit
failed. Ref 510004606
RH Air Data Inertial Reference Unit (ADIRU)
failed. Investigation found a wiring defect at the
terminal block connection where the associated
Pitot and Static ADM receive 13.5VDC from
ADIRU No. 2. Defect due to failure to correctly
insert wire W0523-360R-22 to terminal block
TB522(Y) P/No: S280W555-104 during assembly
of E5-2 electrical shelf at time of aircraft
manufacture. (4 similar occurrences)
Boeing 7378FE Tyre tread separation. Ref 510004577
RH nosewheel tyre tread separated. Damage
caused to the air/ground proximity sensor
circuit, cabling and clamps. The tread had also
damaged the E/E access door handle, dented the
door and the fuselage forward of the door in four
locations. (20 similar occurrences)
Boeing 747338 Empennage structure - lightning
strike. Ref 510004706
Aircraft suffered lightning strike on the
stabilisers. Damage to vertical stabiliser and
horizontal stabiliser.
Boeing 747338 Flight compartment lighting
tube faulty. Ref 510004516
Flight deck fluorescent lighting tube faulty and
smoking. Investigation found the smoke was
coming from the captain’s floodlight assembly.
No faults were found with the unit or wiring.
Boeing 747438 Engine fairing missing. Ref 510004554
No. 1 engine outboard upper ‘A’ frame fairing
missing. (21 similar occurrences)
Boeing 747438 Leading edge flap control unit
failed. Ref 510004708
Leading edge Flap Control Unit (FCU) failed.
Boeing 747438 Rudder power control module
housing cracked. Ref 510004479
Lower rudder power control module housing
cracked. Loss of hydraulic fluid. Investigation
continuing. P/No: 3332001007.
Boeing 747438 Rudder power control module
leaking. Ref 510004549
Upper rudder Power Control Module (PCM)
leaking. Loss of hydraulic fluid. Investigation
continuing. P/No: 3327001007.
Boeing 747438 Trailing edge flap seal missing.
Ref 510004664
LH No. 2 flap canoe rubber seal separated from
aircraft. Investigation continuing.
Boeing 747438 Tyre failed. Ref 510004584
LH main landing gear No. 8 tyre failed on takeoff.
Damage to LH body gear main loom conduit
assembly. Damage to aft body panels P/No:
JULY–AUGUST 2007 FLIGHT SAFETY AUSTRALIA 31
SERVICE DIFFICULTY REPORTS AIRWORTHINESS PULL-OUT SECTION
65B06732, P/No: 65B06731 and P/No: 65B06744.
(21 similar occurrences)
Boeing 767336 Air airconditioning system
- smoke/fumes. Ref 510004709
Oil smell on flight deck. Investigation of the
airconditioning and pressurisation systems could
find no cause.
Boeing 767336 Air distribution system - cabin
odour. Ref 510004672
Fuel fumes contaminated cabin during refuelling.
Boeing 767336 Galley coffee maker faulty. Ref 510004474
No. 1 forward galley coffee brewer faulty. Smoke
and electrical smell emanating from brewer.
Investigation found a failed hot water tank heater
element, P/No: 440-0150-3. The subject heater
cartridge outer sheath had burst, and one of the
wiring terminations had become detached from
the main body of the heater.
P/No: QB611801. TSN: 506,682 hours/TSO: 5,995
hours. (1 similar occurrences)
Boeing 767338ER Air data computer suspect
faulty. Ref 510004739
Captain’s and first officer’s primary altimeters
disagreed. Suspect faulty air data computer
(ADC). Investigation continuing.
P/No: 4040800906. TSN: 519,959 hours. TSO: 14,227 hours. (2 similar occurrences)
Boeing 767338ER Cabin airconditioning
suspect faulty. Ref 510004624
LH airconditioning pack overheat message
combined with smoke and fumes in cabin.
Investigation continuing.
Boeing 767338ER Captains seat loose. Ref 510004668
Captain’s seat loose. Knocking noise when seat
rocked from side to side. Investigation found trucks
(4 of) loose in fittings. (1 similar occurrence)
Boeing 767338ER Emergency exit relay failed
during ‘squib’ test. Ref 510004540
LH overwing emergency escape door failed squib
test. Investigation found relay K3 hanging up. The
defect occurred again and the fault was traced to
relay K1 PNo X-D4L-015. P/No: XD4L015.
Bombardier DHC8201 Trailing edge flap system
overspeed. Ref 510004571
Trailing edge flap inspection required for overspeed
condition. Inspection carried out with nil defects
found.
Bombardier DHC8315 Drag control system
cable incorrectly fitted. Ref 510004555
(photo below)
Roll spoiler cable disconnect sensing system
incorrectly installed. Upper cable fairlead roller
and nylon guide transposed.
32
FLIGHT SAFETY AUSTRALIA JULY–AUGUST 2007
Canadair CL6002B19 Landing gear failed to
extend Ref 510004568
Main landing gear failed to unlock. Nose landing
gear operation normal. Alternate extension
carried out. Retraction tests in hangar could not
replicate fault. Bypass valve and selector valve
replaced. Aircraft now serviceable.
Embraer EMB120 Engine fire detector worn/
damaged. Ref 510004572
RH engine fire detector sense element broken
into two pieces in an area where it had been
chafing against the adjacent structure/
component. P/No: 360175450450F58M.
Fokker F27MK50 Wing crack running from fuel
drain. Ref 510004505
Wing cracked in two places from fuel drain.
One crack emanated forwards from the centre
of the fuel drain radiating through the bolt hole
and terminating at the forward rivet. One crack
emanated rearwards from the centre of the fuel
drain through the bolt hole and terminating at the
aft rivet. Crack lengths approximately 20 mm.
Found during NDT inspection.
Fokker F28MK0100 Lighting system odour. Ref 510004485
Report of smoke smell from cabin light control
panel adjacent to passenger door. Investigation
could find no evidence of burning. The front
face of the panel was wet from rain. The airstair
cupboard curtain was also wet and it was found
that the smell of the curtain was the reported
smoke smell.
Fokker F28MK0100 Standby AH emergency
power supply failed. Ref 510004486
Standby artificial horizon emergency power
supply failed. Burning smell coming from power
supply. Power supply appears to have also
damaged the internals of the standby artificial
horizon. P/No: 171BS1011.
Fokker F28MK0100 Windshield cracked. Ref
510004587
RH windshield cracked. Inspection found three
large cracks running horizontally from left to
right through the centre of the windshield.
P/No: D20543406. (7 similar occurrences)
Saab SF340B Landing gear emergency
extension valve binding. Ref 510004512
Landing gear emergency extension valve binding.
P/No: 683702. (3 similar occurrences)
Saab SF340B Main wheel flange cracked. Ref
510004716 (photo below)
No. 3 main wheel flange cracked through.
Suspect crack initiated from stamped lettering
in flange outer circumference. P/No: 5010489.
TSN: 12,357 hours/15,404 cycles. TSO: 966
hours/1078 cycles. (1 similar occurrence)
AIRCRAFT BELOW 5700 KG
Beech 200 Wing spar cracked. Ref 510004619
LH wing flap track rivets working and cracks in
stiffeners and clips attaching flap track to rear
wing spar. Following removal of the flap track a
25.5mm (1in) crack was found in the rear spar and
a 63.5mm (2.5in) crack was found in the stiffener
attaching wing rib to the rear spar.
TSN: 22,338 hours/18,910 cycles/18,910/
landings/324 months.
Beech 58 Alternator bearing failed. Ref 510004704
RH engine alternator failed. Investigation found
the front bearing collapsed causing the drive
gear to fail. Alternator drive gear in engine
cracked and gear retaining bolts loosened and
failed. Metal contamination of engine.
P/No: ALT9552R. TSO: 156 hours. (5 similar occurrences)
Beech 76 Main landing gear strut pin missing.
Ref 510004711
RH main landing gear shock strut pin missing.
Suspect pin failed and fell out. P/No: 1058100261.
TSN: 10,683 hours.
Britten Norman BN2A26 Aileron push/pull rod
end worn and jammed. Ref 510004625
Aileron push/pull rod end bearing worn and
jammed. Suspect incorrect manufacture of
rodend or bearing. P/No: RBJ342. TSN: 98 hours.
TSO: 98 hours.
Britten Norman BN2A26 Elevator push/pull rod
end worn and jammed. Ref 510004626
Elevator push/pull rod end bearing worn and
jammed. Suspect incorrect manufacture of
rodend or bearing. P/No: RBJ341. TSN: 98 hours.
TSO: 98 hours.
Cessna 208B Blower wiring burnt. Ref 510004561
Wiring located behind instrument and circuit
breaker panels burnt. Investigation found
that the wiring to the blower had chafed on an
airconditioning unit hose clamp. Blower wiring
and other wires damaged. Blower circuit breaker
had ‘popped’ but had been reset.
Cessna 310Q Engine mount frame cracked. Ref 510004707
Lower engine frame cracked. Crack originates
from a stress raiser caused by rubbing on the
heat shield.
Cessna 310R Horizontal stabiliser rear spar
lower angle corroded. Ref 510004702
Horizontal stabiliser RH rear spar lower angle
corroded. Found during SID inspection.
TSN: 5,103 hours. (2 similar occurrences)
Cessna 402C Wing spar damaged. Ref 510004536
RH wing lower forward spar had been drilled in
two places rendering it structurally unsound.
Personnel/maintenance error.
(1 similar occurrence)
Cessna 404 Main landing gear uplock hook
cracked. Ref 510004595
LH main landing gear uplock hook cracked.
P/No: 574122215.
Cessna 404 Wing rib panel loose. Ref 510004589
Panel located on rib assembly P/No: 5822433-3
loose. Panel restricted aileron movement when
flaps lowered. Personnel/maintenance error.
Cessna 414A Wing spar strap damaged. Ref 510004675
LH wing doubler/spar strap located at WS 60-77
scratched. Further inspection found drilling swarf
between attachment surfaces causing deep
scratch marks. Found during SID inspection.
Cessna A37B Wing attach fitting cracked. Ref 510004510
LH forward wing attachment fitting cracked.
Crack length 76.2 mm. P/No: 41113211. TSN: 1,536 hours.
Cirrus SR22 Aircraft fuel system contaminated.
Ref 510004679
Fuel system contamination. Fuel pump, metering
unit and manifold valve replaced.
DeHavilland DH82A Main landing gear lower
fork fitting failed. Ref 510004488
RH main landing gear lower fork fitting failed
in bolt head radius. Fork bolt PNo H24060 had
not been modified iaw AD/DH82/1 Req2. P/No:
HF5000. TSN: 780 hours. (1 similar occurrence)
Diamond DA42 Central display PFD screen
unserviceable. Ref 510004498
Smoke emanating from primary flight display
(PFD) screen. Smoke lasted for approximately 3
seconds then stopped. PFD replaced.
P/No: 0110097202. TSN: 66 hours. TSO: 66
hours.
Gippsland GA8 Power distribution system
solenoid failed. Ref 510004468
Bus 2 solenoid failed. P/No: ASHDOWN2524059.
TSN: 1,949 hours.
Gulfstream 500S Emergency exit window
separated. Ref 510004684
Emergency window/exit separated from aircraft.
Investigation found the retaining pins were not
engaged in the exit hinge halves following AD/
Gen/37. P/No: 860306137.
Kavanagh E210 Balloon burner gimbal
mounting bracket failed. Ref 510004490
(photo below)
Balloon burner gimbal mounting bracket failed.
P/No: CB8720C1030. TSN: 433 hours/450
cycles.
Pilatus PC12 Stickpusher computer failed test.
Ref 510004475
Stickpusher computer failed preflight test.
P/No: 9754423104. TSN: 7,306 hours/6,006
cycles. TSO: 7,306 hours/6,006 cycles. (3 similar occurrences)
Pilatus PC12 Propeller de-ice harness wire
broken. Ref 510004476
Propeller de-ice harness wire broken at bend in
harness. P/No: 3E23604. (28 similar occurrences)
Piper PA30 Nose wheel steering arm attach
bolts failed. Ref 510004728
Nose wheel steering arm assembly attachment
bolts pulled out of the nose oleo P/No: 21707-00.
Steering arm assembly P/No: 44386-00 separated
and fell onto runway. Three attachment bolts P/
No: 402800 (NAS1303-8H) and lockwire have not
been found. P/No: 402800.
Piper PA32R301 Rudder trim arm cracked/
separated. Ref 510004547 (photo right)
Rudder trim arm cracked and separated. Found
during inspection iaw AD/PA32/15 A2.
P/No: 63457004. (1 similar occurrence)
Reims F406 Autopilot roll servo jammed. Ref 510004632
Autopilot roll servo jammed.
P/No: 065005650.
Swearingen SA227DC Fuel indicating system
loom frayed. Ref 510004526
LH and RH fuel tank fuel quantity system wiring
looms frayed. (2 similar occurrences)
ROTORCRAFT
Bell 206B Main rotor blade cracked. Ref 510004608
Main rotor blade cracked chordwise through
the blade trailing edge. Crack was located
approximately 1.5 metres from the inboard root.
Cracking was through both upper and lower skins
and was approximately 200 mm long in each skin.
TSO: 2,913 hours. (2 similar occurrences)
Bell 206B3 Electrical system faulty. Ref 510004732
Electrical system faulty. Operation of N2
governor linear actuator ‘beep’ switch also
operates cargo hook release. Operation of
electrical cargo release switch also operates N2
linear actuator. Investigation continuing.
Bell 412 Main rotor blade trim tab disbonded.
Ref 510004566 (photo below)
Main rotor blade mid span trailing edge trim tab
disbonded and peeled back in flight. Two other
tabs found to be disbonding. Suspect incorrect
bonding technique. P/No: 412015207107. TSN: 70
hours.
Bell 412 Tail rotor blade bolt sheared. Ref 510004500 (photo right)
Tail rotor pitch horn to blade attachment bolt
sheared. Suspect failure initiated from corrosion
on bolt shank. P/No: EWB26434. (1 similar
occurrence)
Eurocopter AS355F1 Main rotor head bearing
debonded. Ref 510004628
Main rotor head spherical thrust bearing bonding
failed. Area of debonding approximately 20mm .
P/No: 57910700. TSN: 3,715 hours/120 months.
Eurocopter AS365N Main rotor head frequency
adaptor cracked. Ref 510004585
Main rotor head frequency adaptor cracked.
Further inspection found two more smaller
cracks starting on both sides. P/No: E1T302301A.
TSN: 1,327 hours/132 months. TSO: 1,327
hours/132 months.
Robinson R22BETA Main rotor blade cracked.
Ref 510004499
Indications of cracking on main rotor blade
top skin. When the area was rubbed back and
inspected, it was found that the blade had
been struck by a hard object which dented and
cracked the skin beyond limits. The blade then
had an unapproved repair carried out consisting
of filling the dent with filler and repainting to the
original surface condition covering the damaged
area. The blade was removed and replaced.
Unapproved repair. Personnel/maintenance
error. P/No: A0164. TSN: 685 hours. (1 similar
occurrence)
Robinson R22BETA Main rotor blade root fitting
bore worn. Ref 510004738
Main rotor blade root fitting bore worn beyond
limits. Found following removal of spindle and
bearing for replacement. P/No: A0164. TSN: 779
hours.
Robinson R22BETA Main rotor control rod end
broken. Ref 510004622
Collective control lower rodend failed in threaded
section. Collective spring rod end plate PNo A426-2
guide holes worn allowing guide rods to jam causing
a bending moment on the rodend and causing it to
fail. P/No: A1273. TSN: 2,100 hours.
Robinson R44 Engine/transmission coupling
clutch failed. Ref 510004575
Engine to transmission sprag clutch notchy and
dragging.
P/No: C1883. TSN: 1,071 hours. (1 similar
occurrence)
Robinson R44 Main rotor transmission mount
damaged. Ref 510004590
Main rotor gearbox forward mounts compressed.
P/No: A6531. TSN: 101 hours.
PISTON ENGINES
Continental GTSIO520M Engine exhaust
transition faulty. Ref 510004579
RH engine exhaust transition faulty. Following
fitment of a new turbocharger, wastegate and
two new cylinders, the manifold pressure was
high and unable to be adjusted to within limits.
P/No: AEA4083. (4 similar occurrences)
Continental IO360E Engine fuel filter
contaminated. Ref 510004663
Fuel manifold valve filter contaminated and
piston seat damaged. Airframe fuel filter and fuel
tank also contaminated. Suspect contamination
is fuel tank assembly material.
(2 similar occurrences)
Continental IO520F Engine camshaft worn. Ref 510004524
Camshaft lobes worn. Surface of cam follower
exhibited signs of erosion. Metal contamination
of engine oil system. TSN: 1,558 hours.
Continental IO520F Engine cylinder cracked.
Ref 510004655
Engine No. 2 cylinder head cracked around
circumference and separated from barrel.
JULY–AUGUST 2007 FLIGHT SAFETY AUSTRALIA 33
SERVICE DIFFICULTY REPORTS AIRWORTHINESS PULL-OUT SECTION
P/No: AEC631397SN712REVP. TSO: 1,276 hours.
(15 similar occurrences)
Continental IO520F Engine cylinder gasket
incorrect fit. Ref 510004462
Induction manifold to cylinder gaskets incorrectly
fitted. One bolt in the same position on each
cylinder manifold was not going through the
gasket. This allowed unfiltered air to be sucked
into each cylinder which caused lean running.
P/No: 649959. (1 similar occurrence)
Continental IO550N Engine cylinder loose. Ref 510004724
LH rear cylinder loose. Loss of engine oil
followed by engine failure. Cylinders had been
fitted approximately two hours previously.
TSN: 140 hours. (5 similar occurrences)
Continental IO550N Engine fuel filter
contaminated. Ref 510004656
Fuel manifold valve filter contaminated.
Airframe fuel filter also contaminated. Suspect
contamination is fuel tank assembly material.
P/No: AFFMY. (6 similar occurrences)
Lycoming IO360A3B6 Engine starter motor
faulty. Ref 510004640
Engine starter motor faulty. Starter failed to
engage ring gear. Suspect internal failure of
drive gear. TSN: 185 hours.
Lycoming IO540E1B5 Engine fuel filter
contaminated. Ref 510004508
LH engine vapour separator ejector blocked
resulting in excessive pressure on upper side of
fuel manifold and forcing the manifold valve into
the shutoff position.
Lycoming IO540K1A5 Engine fuel injector line
damaged. Ref 510004467
No. 2 cylinder fuel injector line damaged and leaking
around seam near fuel line nut. P/No: LW120980280.
TSO: 192 hours. (3 similar occurrences)
Lycoming IO540K1A5 Engine fuel pump
unserviceable. Ref 510004586
Engine driven fuel pump faulty. Investigation found
that when the electric boost pump was turned on,
a solid stream of fuel was ejected from the engine
driven fuel pump head drain.
TSO: 463 hours. (12 similar occurrences)
Lycoming IO540K1B5 Engine fuel hose
incorrectly routed. Ref 510004567
RH engine fuel hose from engine driven pump
to ‘digidata’ incorrectly routed near exhaust
system crossover pipe. Incorrect fit.
Lycoming O320D2J Engine cylinder head
separated. Ref 510004562
No. 4 cylinder head separated from cylinder
barrel. P/No: AEL850991R. TSN: 315 hours/23
months. (1 similar occurrence)
Lycoming O320D3G Carburettor float
contaminated. Ref 510004588 (photo right)
Carburettor float found to be approximately
half full of fuel. Investigation found no apparent
damage to the float. The fuel is trapped in the
float and shows no signs of leaking out through
the manufacturing joint. P/No: 30804. TSN: 1,289
hours. (1 similar occurrence)
Lycoming O360F1A6 Engine exhaust system
faulty. Ref 510004543
Exhaust system and muffler unserviceable. AD/
C170/48 carried out 35.9 hours previously.
P/No: K156020. (1 similar occurrence)
Rotax ROTAX912 Engine exhaust shroud ring
broken. Ref 510004531
Engine exhaust shroud support ring broken.
Failed piece of support ring entered engine
cylinder and held inlet and exhaust valves open.
TURBINE ENGINES
Allison 501D13 Engine compressor rubbing.
Ref 510004504
RH engine rotation slow and noisy. Signs of
compressor rub. Engine removed for further
investigation. P/No: 501D13. TSN: 370 hours/220
cycles. TSO: 370 hours/220 cycles.
GE CF680C2 Thrust reverser relay incorrectly
fitted. Ref 510004481
No. 2, No. 3 and No. 4 engine thrust reverser
relays fitted backwards. P/No: 7363.
GE CFM563C Engine accessory drive bearing
failed. Ref 510004497
No. 1 engine forward sump chip detector
contaminated with metal. Engine removed.
Investigation found No. 3 bearing damaged.
Bearing cage outer diameter damaged due to
wear with the bearing outer race.
P/No: 1461M14PO4. (5 similar occurrences)
Lycoming ALF502R5 Engine fuel manifold fire.
Ref 510004633
No. 3 engine RH fuel manifold fire. Fire wire
support clip melted in 6 o’clock position.
Investigation continuing. P/No: 21636203737.
TSO: 4,674 hours/2,864 cycles. (1 similar
occurrence)
PWA JT8D15 Engine PT7 line broken. Ref 510004492
No. 2 engine PT7 line on manifold broken.
P/No: 500805.
PWA JT8D219 Engine fuel pump leaking. Ref 510004636
LH engine driven fuel pump leaking due to worn
driveshaft. P/No: 33442. TSN: 20 hours. TSO:
20 hours.
PWA PW118A Engine oil system pipe cracked.
Ref 510004665
LH engine No. 6/No. 7 bearing oil line cracked
and leaking at a point approximately half way
along the length of the pipe. P/No: 3035197. TSN:
30,880 hours. (2 similar occurrences)
PWA PW123E Engine reduction gear cracked.
Ref 510004534
RH engine reduction gearbox second stage bull
gear cracked in three places extending from the
No. 15 bearing mating face towards the gear hub.
(1 similar occurrence)
Rolls Royce RB211524G Engine accessory drive
bolt incorrect part. Ref 510004489
No. 2 engine low oil pressure and high oil quantity
indications. Investigation found the oil was
leaking from the blanked internal gearbox chip
detector plate. Removal of the blanking plate
found that no ‘O’ ring seal had been fitted.
Investigation also found that one of the high
speed gearbox primary pressure pump relief
valve attachment bolts was longer than the other
two. A faulty oil quantity transmitter contained
two dry solder joints. TSN: 27,245 hours.
Rolls Royce RB211524G Engine compressor
failed. Ref 510004493
No. 1 engine failed. Metal deposits in tailpipe.
Boroscope inspection found high pressure
compressor (HPC) blade root failure.
Investigation found that the HPC was severely
damaged and had evidence of a titanium fire. The
borescope inspection also found damage to the
6th and 7th (last) stage of the IPC rotor blades,
mainly in the form of minor trailing edge FOD
and tip rubs. One blade in the IPC 7th stage had
a crescent shaped tear in the B zone that was
outside engine manual limits. P/No: RB211524G.
TSN: 62,777 hours. TSO: 16,728 hours. (1 similar
occurrence)
Rolls Royce RB211524H Thrust reverser
blocker door damaged. Ref 510004715
No. 1 engine thrust reverser outboard uppermost
blocker door section missing.
(5 similar occurrences)
Turbomeca ARRIEL2B Engine reduction gear
nut broken. Ref 510004683
Engine module 5 magnetic chip detector
contained a large metal chip approximately 3mm
by 4mm (0.118in by 0.157in). The metal particle
was identified as part of a nut. Module was
removed and sent to the manufacturer for further
investigation. TSN: 921 hours.
Turbomeca ARRIEL2B Engine bleed air system
pipe broken. Ref 510004673
Engine P3 air supply pipe to power turbine
labyrinth seal broken. Found during inspection
iaw SB 292-75-2141. P/No: 0292687310.
PROPELLERS
McCauley 4HFR34C653 Propeller governor
unserviceable. Ref 510004615
LH propeller governor unserviceable.
P/No: 89741016. TSO: 6,517 hours. (2 similar
occurrence)
Note: Occurrence figures based on data received
over the past 5 years. ■
SERVICE DIFFICULTy REPORTS
To report urgent defects
call 131757 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
34
FLIGHT SAFETY AUSTRALIA JULY–AUGUST 2007
AIRWORTHINESS PULL-OUT SECTION
Continued from p. 30
awl to probe material in suspected spots,
if required; some manufacturers require
an eddy current inspection as well
• damaged or missing heat studs, fins, or
other heat sink material; minor defects
such as these may cause uneven heating of
the muffler surface and lead to holes in the
muffler can
• inner wall surface – use boroscope and
inspect internal areas for wear, pitting,
cracks, and broken baffles; corrosion may
be occurring in a component that looks
good externally
• clamp connections, attachments, tail
pipes and stacks – for looseness, cracks,
dents or damage
• welded areas and stack bends, for
cracks
• If the muffler has internal baffles or
tubes, check for damaged or missing
baffles. If this is the case, simply replace
the muffler. Baffles distribute heat and
create back pressure (part of the engine
design) but unfortunately deteriorate
before the walls of the muffler do.
Damaged baffles can also create
localised hot spots, weakening or burning
through the muffler metal. If not replaced
on time, baffles can dislodge and cause
restrictions to the exhaust system and
may lead to engine failure. Missing baffles
can reduce the efficiency of the heating
system to the tune of 50–60 per cent.
•Y-assembly/exhaust header – especially
on Cessna turbo 182 aircraft. There is no
support bracket in T182 for the turbocharger, and all of the weight of the turbo
rests on the Y-assembly/exhaust header,
putting a lot of stress on that header. There
have been several of these exhaust headers
that have cracked and broken. This can
cause an in-flight fire.
• Check pilot reports if engine experiences backfire or an after-fire. Such
anomalies are extremely hard on exhaust
systems, especially mufflered ones,
stressing the entire exhaust system in an
abrupt, severe manner and can damage
baff les (even breaking them loose) and
may also bulge or crack the can. Any
reports as such warrant a thorough
‘If there are complaints of headacheS
and nausea from the pilots, it’s time to
check the cabin for proper sealing.’
inspection of the entire exhaust system.
In addition to the parts normally
associated with the exhaust system, also
inspect the turbocharger system for the
following:
• improper
installation,
including
misalignment of exhaust stacks, ball
joints, and/or connections which results
in abnormal wear
• housings for cracks and wear
• oil reservoir for improper service.
While inspecting exhaust system
components, don’t forget to check that:
• no part of the system is being chafed by
cowling, cables, or other parts
•Firewall seal(s) are in good condition,
to ensure that exhaust gases will not enter
the cabin area. Check all possible entry
points for exhaust gas – e.g. strut fairings (on high-wing single Cessna aircraft)
or deteriorated nose wheel steering rod
boots. If there are complaints of headache
and nausea from the pilots, it’s time to
check the cabin for proper sealing.
• the engine compartment is clean and
free of combustible material such as oil.
Do not mark any surfaces with lead
pencils or any carbon-containing markers.
Exhaust system component material may
react at elevated temperatures and crack.
Any damage to an exhaust system component usually requires the entire component to be overhauled or replaced, as spot
welds and patch repairs are not known to
last long.
When you install the exhaust system
back in, the following steps are recommended:
• do not reuse gaskets
• use an anti-seize compound suitable for
high temperatures on all slip joints
• use correct and approved parts only
and follow respective instructions for
continued airworthiness.
• do not force-fit any parts; cracking will
occur and shorten component service life
– stacks forced to fit and having a preload
on the system, and then going through
several heating and cooling cycles
combined with vibration is an invitation
for cracks to begin
• ensure that all parts are aligned properly; first loosely mount on aircraft then
tighten evenly all connectors to OEM
specifications – retighten after a hot run
‘Tuned’ exhaust systems offer STC variation to the ‘traditional’ exhaust systems,
incorporating longer exhaust tubes to
optimise the way exhaust gases escape
out of cylinders. Tuned exhaust systems,
where installed, should be maintained
according to the instructions of continuing airworthiness (ICA) provided by the
STC holder.
When to inspect an aircraft’s exhaust
system depends on your elected maintenance schedule and what/how to inspect
is usually provided by the aircraft manufacturer in service documents. Always
follow manufacturer’s advice. In a rare
case where manufacturers’ service documents are silent on the subject, FAA AC
91-59 (Inspection and care of General
Aviation Aircraft Exhaust Systems) and
FAA AC 43-13-1B – Chapter 8 (Engines,
Fuel, Exhaust and Propellers) provide
good general advice.
Remember, aircraft exhaust systems
are not designed for an infinite life and
there should be plans in place for periodic replacement. Be fair and kind to the
exhaust system and it will be fair and kind
to you in return. ■
– Obaid Soomro is a technical specialist
in CASA’s propulsion and mechanical
systems section
MAY–JUNE 2007 FLIGHT SAFETY AUSTRALIA 35
AIRWORTHINESS DIRECTIVES PULL-OUT SECTION
Approved Airworthiness Directives
5 July 2007
Part 39-105 - Lighter Than Air
There are no amendments to Part 39-105
- Lighter than Air this issue
Part 39-105 - Rotorcraft
Aircraft - General
AD/GENERAL/66 Amdt 1 - Floor Proximity
Escape Path Marking
Bell Helicopter Textron Canada (BHTC) 206
and Agusta Bell 206 Series Helicopters
AD/BELL 206/166 Amdt 1 - Main Rotor
Latch Bolts
AD/BELL 206/167 Amdt 1 - Transmission
Pylon Support Spindle
AD/BELL 206/170 - Horizontal Stabiliser
Skin at the Tailboom Attachment Inserts
Bell Helicopter Textron Canada (BHTC) 407
Series Helicopters
AD/BELL 407/29 - Horizontal Stabiliser
Skin at the Tailboom Attachment Inserts
Bell Helicopter Textron Canada (BHTC)
430 Series Helicopters
AD/BELL 430/10 - Tail Rotor Pitch Change
Mechanism
Eurocopter AS 350 (Ecureuil) Series
Helicopters
AD/ECUREUIL/71 Amdt 2 - Tail Rotor Blade
Trailing Edge
AD/ECUREUIL/122 Amdt 1 - Emergency
Flotation Gear
AD/ECUREUIL/126 - Fuselage Centre
Cross-Member under Cabin Floor
AD/ECUREUIL/127 - Main & Tail Rotors
Servo Controls
Eurocopter AS 355 (Twin Ecureuil) Series
Helicopters
AD/AS 355/60 Amdt 2 - Tail Rotor Blade
Trailing Edge
AD/AS 355/94 - Load Compensator Levers
AD/AS 355/95 - Fuselage Centre CrossMember under Cabin Floor
AD/AS 355/96 - Main & Tail Rotors Servo
Controls
Eurocopter BK 117 Series Helicopters
AD/GBK 117/17 - Fire Protection System
Clamps
Eurocopter SA 315 (Lama) Series
Helicopters
AD/SA 315/18 - Main Gearbox Oil Acidity
Eurocopter SA 360 and SA 365 (Dauphin)
Series Helicopters
AD/DAUPHIN/46 Amdt 2 - Main Rotor
Gearbox Suspension Diagonal CrossMember
McDonnell Douglas (Hughes) and
Kawasaki 369 Series Helicopters
AD/HU 369/117 - Tail Rotor Blade Root
Fitting
Robinson R44 Series Helicopters
AD/R44/21 - Seat Belt Buckles
Part 39-105 - Below 5700 kg
Aircraft - General
AD/GENERAL/66 Amdt 1 - Floor Proximity
Escape Path Marking
Airtractor 600 Series Aeroplanes
AD/AT 600/7 - Horizontal Stabiliser Brace
Tube Assembly
Beechcraft 65 and 70 (Queen Air) Series
Aeroplanes
AD/BEECH 65/61 Amdt 5 - Nose Gear
Lower Shock Absorber Assembly
Beechcraft 90 and 65-90 (King Air) Series
Aeroplanes
AD/BEECH 90/75 Amdt 5 - Nose Landing
Gear Lower Shock Absorber Assembly
Cessna 208 Series Aeroplanes
AD/CESSNA 208/21 - Low Airspeed
Awareness System
DHC-2 (Beaver) Series Aeroplanes
36
AD/DHC-2/27 Amdt 3 - Horizontal
Stabiliser Front Spar
Pacific Aerospace 750XL Series
Aeroplanes
AD/750XL/12 - Wing Rear Spar
AD/750XL/13 - Aileron Inboard Hinge
Attachment
Part 39-105 - Above 5700 kg
Aircraft - General
AD/GENERAL/66 Amdt 1 - Floor Proximity
Escape Path Marking
Airbus Industrie A330 Series Aeroplanes
AD/A330/13 Amdt 5 - Life Limits/Monitored
Parts
AD/A330/45 Amdt 3 - Wing Rib 6
AD/A330/65 - Main Landing Gear
Retraction Link - CANCELLED
AD/A330/74 - Fuselage Longitudinal Joint
at Stringer 28 RH
Beechcraft 300 Series Aeroplanes
AD/BEECH 300/20 - Nose Gear Lower
Shock Absorber Assembly
Beechcraft 1900 Series Aeroplanes
AD/BEECH 1900/2 Amdt 2 - Nose Gear
Lower Shock Absorber Assembly
Boeing 727 Series Aeroplanes
AD/B727/205 - Fuel Boost Pump Wiring
Boeing 737 Series Aeroplanes
AD/B737/201 Amdt 2 - Rudder Control
System
AD/B737/303 - Fuel Boost Pump Wiring
Boeing 767 Series Aeroplanes
AD/B767/230 - Fire Extinguishing Tube
Chafing
Bombardier (Boeing Canada/De Havilland)
DHC-8 Series Aeroplanes
AD/DHC-8/129 - Corrosion Prevention and
Control Program
Dassault Aviation Falcon 2000 Series
Aeroplanes
AD/F2000/22 - Engine Fire Detection
Systems - CANCELLED
AD/F2000/26 - Engine Fire Detection Units
AD/F2000/27 - Wing Anti-Ice Monitoring
System
Embraer ERJ-170 Series Aeroplanes
AD/ERJ-170/11 - Hydraulic Hose Clamps
Fokker F100 (F28 Mk 100) Series
Aeroplanes
AD/F100/84 - Fuel Crossfeed Valve and Fire
Shut-Off Actuators
Learjet 45 Series Aeroplanes
AD/LJ45/10 - APU Fuel Shutoff Valve
Part 39-106 - Piston Engines
SMA Piston Engines
AD/SMA/3 - Engine Primary Exhaust
Assembly
Part 39-106 - Turbine Engines
CFM International Turbine Engines
- CFM56 Series
AD/CFM56/26 - Low Pressure Turbine Rear
Frame Life
Rolls Royce Germany Turbine Engines
- BR700 Series
AD/BR700/1 - High Pressure Turbine Discs
- CANCELLED
AD/BR700/9 - Fan Disc Retirement Lives
Rolls Royce Turbine Engines - Tay Series
AD/TAY/2 Amdt 2 - Fan Blade Root
- Inspection - CANCELLED
AD/TAY/9 - Ultrasonic Inspection of LP
Compressor Rotor Blades - CANCELLED
AD/TAY/19 - LP Compressor Rotor Blade
Cracking
Turbomeca Turbine Engines - Arriel Series
AD/ARRIEL/19 Amdt 1 - Fuel Metering Unit
Acceleration Controller Axle
Turbomeca Turbine Engines - Arrius Series
AD/ARRIUS/13 Amdt 1 - Gas Generator
Front Bearing
FLIGHT SAFETY AUSTRALIA JULY–AUGUST 2007
Turbomeca Turbine Engines - Makila
Series
AD/MAKILA/7 Amdt 1 - Digital Engine
Control Unit Software
AD/MAKILA/9 - Engine Control Unit
- Comparator/Selection Board
Part 39-107 - Equipment
There are no amendments to Part 39-107
- Equipment this issue
Approved Airworthiness Directives
2 AUGUST 2007
Part 39-105 - Lighter Than Air
There are no amendments to Part 39-105
- Lighter than Air this issue.
Part 39-105 - Rotorcraft
Agusta A109 Series Helicopters
AD/A109/57 - Cargo Hook Installation - 2
Agusta A119 Series Helicopters
AD/A119/9 - Cargo Hook Installation
Bell Helicopter Textron Canada (BHTC)
222 Series Helicopters
AD/BELL 222/36 - Tail Rotor Driveshaft
Thomas Couplings
AD/BELL 222/37 - Tail Rotor Pitch Change
Mechanism
AD/BELL 222/38 - Power Turbine RPM
Steady-State Operation
Eurocopter EC 135 Series Helicopters
AD/EC 135/14 - Direct Current Distribution
- Separation of Wiring
Sikorsky S-76 Series Helicopters
AD/S-76/75 - Main Rotor Shaft - 2
Part 39-105 - Below 5700 kg
Beechcraft 200 (Super King Air) Series
Aeroplanes
AD/BEECH 200/74 - Flight Control System
Cessna 208 Series Aeroplanes
AD/CESSNA 208/21 Amdt 1 - Low Airspeed
Awareness System
Cessna 500 (Citation) Series Aeroplanes
AD/CESSNA 500/29 - Wing Fuel Boost
Pump Wiring
AD/CESSNA 500/30 - Engine Fire Bottle
Wiring
Part 39-105 - Above 5700 kgs
Airbus Industrie A319, A320 and A321
Series Aeroplanes
AD/A320/144 Amdt 2 - Elevator
AD/A320/193 Amdt 2 - Auxiliary Power Unit
Starter and Air Intake System
Airbus Industrie A330 Series Aeroplanes
AD/A330/34 Amdt 1 - MLG Retraction
Actuator Lower Pin
AD/A330/37 Amdt 2 - Elevator
Servocontrols
Avions de Transport Regional ATR 42
Series Aeroplanes
AD/ATR 42/1 - State of Design
Airworthiness Directives
AD/ATR 42/2 - Fuel Tank Safety - Electrical
Wiring
AD/ATR 42/3 - Propeller Pitch Change
System Components
AD/ATR 42/4 - Passenger/Crew Door
Lifting Device
AD/ATR 42/5 - Main Landing Gear Side
Brace Assembly
AD/ATR 42/6 - Vertical Stabiliser Fin Tip
AD/ATR 42/7 - Aileron Tab Bellcrank
Assembly
AD/ATR 42/8 - Time Limits
AD/ATR 42/9 - Outer Wings
AD/ATR 42/10 - Main Landing Gear Side
Brace Lower Arm
AD/ATR 42/11 - Structural Modification
AD/ATR 42/12 - Main Landing Gear Wheels
Beechcraft 300 Series Aeroplanes
AD/BEECH 300/21 - Flight Control System
Boeing 717 Series Aeroplanes
AD/B717/11 Amdt 1 - Safe-Life Structure
and Principal Structural Elements
AD/B717/21 - Fuel System Lightning
Protection
Boeing 727 Series Aeroplanes
AD/B727/205 Amdt 1 - Fuel Boost Pump
Wiring
AD/B727/206 - Forward Entry Door Hinge
Cutouts
Boeing 737 Series Aeroplanes
AD/B737/304 - Flight Deck Door Wiring
Looms
Boeing 747 Series Aeroplanes
AD/B747/46 Amdt 7 - Forward Fuselage
Pressure Shell
AD/B747/170 Amdt 1 - Main Entry Door Girt
Bar Support Fitting
AD/B747/323 Amdt 2 - Nose Wheel Well
Top and Side Panel Webs and Stiffeners
AD/B747/357 - Station 400 Upper Deck
Floor Beam
Bombardier (Canadair) CL-600 (Challenger)
Series Aeroplanes
AD/CL-600/41 Amdt 1 - Fire Warning
Control Unit
AD/CL-600/70 - AC Contactors
AD/CL-600/71 - State of Design
Airworthiness Directives
AD/CL-600/72 - Thrust Reverser Casades
Configuration
AD/CL-600/73 - Main Landing Gear Main
Fitting - 2
AD/CL-600/74 - Horizontal Stabiliser Trim
Actuator Secondary Load Path Indicator
AD/CL-600/75 - Structural Inspection
Program Revision
Bombardier (Boeing Canada/De Havilland)
DHC-8 Series Aeroplanes
AD/DHC-8/130 - Forward Baggage
Translating Door Spring Assembly Bracket
AD/DHC-8/131 - Spring Tab Mechanism
Bolts
Cessna 550 (Citation II) Series Aeroplanes
AD/CESSNA 550/25 Amdt 1 - Engine Fire
Bottle Wiring
Embraer EMB-120 (Brasilia) Series
Aeroplanes
AD/EMB-120/46 - Fuel System
Gulfstream (Grumman) G1159 and G-IV
Series Aeroplanes
AD/G1159/46 - State of Design
Airworthiness Directives
AD/G1159/47 - Nose Wheel Steering
Control
AD/G1159/48 - Roll Axis Hardover
Protection System
Part 39-106 - Piston Engines
There are no amendments to Part 39-106
- Piston Engines this issue.
Part 39-106 - Turbine Engines
General Electric Turbine Engines - CF6
Series
AD/CF6/64 - Fuel Shroud Retaining Snap
Ring
AD/CF6/65 - ECU Software Upgrade
AD/CF6/66 - Uncontained Fan Blade Failure
General Electric Turbine Engines - CF34
Series
AD/CF34/14 - Combustor Case Life Limits
Rolls Royce Germany Turbine Engines
- BR700 Series
AD/BR700/10 Amdt 1 - High Pressure
Turbine Time Limits
Turbomeca Turbine Engines - Arrius Series
AD/ARRIUS/13 Amdt 2 - Gas Generator
Front Bearing
Part 39-107 - Equipment
Auxiliary Power Units
AD/APU/21 - RE220 Fuel Nozzles