CONTENTS | ARTICLES | AIRWORTHINESS | REGULARS · PDF fileAirbus A330-202 Air ......

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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

Transcript of CONTENTS | ARTICLES | AIRWORTHINESS | REGULARS · PDF fileAirbus A330-202 Air ......

44 CONTENTS | ARTICLES | AIRWORTHINESS | REGULARSService difficulty reports

7 August – 17 September 2013Note: Similar occurrence figures not included in this edition

ABOVE 5700kg Airbus A320-232 Aerodynamic fairing – tail cone damaged. SDR 510017442Aircraft tail cone suffered extensive damage when contacted by the wingtip of another aircraft. Investigation continuing.Airbus A320-232 APU oil cooler leaking. SDR 510017590APU oil cooler leaking. Investigation continuing. P/No: 1604941. TSN: 12982 hours/11145 cyclesAirbus A320-232 Battery unserviceable. SDR 510017620Light electrical smell. Investigation found spare battery in galley box arcing. Investigation continuing.P/No: BIM81XX1K9KGX.Airbus A320-232 Control column section – connector loose. SDR 510017480First 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 510017523ELT 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 510017472Smell/smoke in cockpit and cabin. Investigation found RH recirculation fan faulty. Investigation continuing. P/No: VR410004. TSN: 981 hours. TSO: 981 hoursAirbus A330-243 Aircraft fuel distribution system – actuator faulty. SDR 510017543Inner fuel tank inlet valve actuator (603QL1) faulty. P/No: D97C00654.Airbus A380-842 Landing gear position and warning system – proximity sensor failed. SDR 510017608LH 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 510017592Vertical stabiliser front spar attachment fitting plate corroded. P/No: 305111. TSN: 1,987 hours/84 monthsATR ATR72212A Brake anti-skid section – module failed. SDR 510017517Anti-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 510017433Captain's seat fore/aft lock spring broken. Two similar defects. P/No: 1A5270016. TSN: 4351 hours/4190 cycles/28 monthsBAC 146-100 Hydraulic system main – hose holed. SDR 510017513Yellow 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 510017460No. 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 510017431Burning 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 510017459No. 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

45FLIGHT SAFETY AUSTRALIAIssue 94 September–October 2013

Boeing 737-3YO Fuselage plates/skin – skin cracked. SDR 510017439Fuselage 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 510017426APU oil cooler fins heavily contaminated causing high oil temperatures. P/No: 1605642.Boeing 737-838 ATC transponder system – switch faulty. SDR 510017462ATC 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 510017482RH 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 510017629Centre 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.

Boeing 737-838 Wheel bolt sheared. SDR 510017527LH outboard main wheel tie bolt (2off) sheared. One similar defect. P/No: 277A6000204. TSN: 10707 hours TSO: 551 hours

Boeing 737-8FE APU bleed valve unserviceable. SDR 510017562APU 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 cyclesBoeing 737-8FE Outside air temperature indicator/sensor – probe unserviceable. SDR 510017467Total air temperature (TAT) probe damaged by contact with aero bridge.Boeing 737-8FE Passenger/crew door seal FOD. SDR 510017458Loud 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 510017494Standby hydraulic pump wiring bundle W8538 chafing and short circuiting on fairing. Investigation found wiring loom slack. P/No: W8538.

Boeing 767-338ER APU cowlings/containment – APU leaking. SDR 510017502Oil 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 510017471LH 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 | REGULARSService difficulty reports

Boeing 777-3ZGER Exterior lighting – light unserviceable. SDR 510017530Tail light burnt out. Suspect internal arcing. Investigation continuing. P/No: 3024813. TSN: 19724 hours/1,625 cycles

Boeing 777-3ZGER Hydraulic system hose cracked and leaking. SDR 510017558Hydraulic hose to elevator PCU leaking. Hose has a Kevlar inner lining which cracks/ruptures allowing fluid leakage. 1 similar defect. P/No: AS4568J0444SS.Bombardier DHC8-102 Engine oil cooler – oil cooler leaking. SDR 510017419RH engine oil cooler leaking. Investigation found one of the inlet fitting helicoils had dislodged, allowing oil to bypass and leak. Cooler was an overhauled item that had failed on the first flight after fitment. One similar defect. P/No: 28E997. TSO: 1 hourBombardier DHC8-311 Landing gear retraction system suspect faulty. SDR 510017420Nose landing gear failed to retract. Investigation found no definitive cause for the defect and further retraction tests could not fault the system.Bombardier DHC8-314 Emergency equipment system – ditching dam inadvertent operation. SDR 510017469RH ditching dam deployed and was slightly inflated during flight. Inflation line open to cabin pressure and rupture disc burst. P/No: 4MA102510.

Bombardier DHC8-315 Hydraulic pressure regulator main - regulator faulty. SDR 510017479No2 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 510017473Landing 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 510017601Investigation found pitot/static heat system circuit breaker popped. CB reset and system tested serviceable.Bombardier DHC8-402 Aileron control system cable worn. SDR 510017561LH and RH aileron cables worn beyond limits. P/No: 82742407001. TSN: 15657 hours/17890 cyclesNo.1 Multi-function display unit suspect faulty. Investigation continuing.Bombardier DHC8-402 Door warning system washer worn. SDR 510017612Forward 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 510017575Engine warning light illuminated. Initial investigation could not rectify fault. RH High-pressure shutoff valve (HPSOV) faulty. P/No: 2005100618.Convair 340 Engine emergency shutdown system – switch corroded. SDR 510017526LH engine emergency shutdown switch plunger shaft retaining ring corroded, with ring eventually failing. Found during inspection iaw SL 580-76-001. P/No: 8PB1.Fokker F27MK50 Passenger seats – cross members cracked. SDR 510017560Passenger seat aisle cross members cracked on seats 2DF and 8DF. Found during inspection iaw AD/Seat/ 16 A1 and CSB 312/912-02 Rev 1.Fokker F27MK50 Power lever stiff. SDR 510017595RH power lever stiff in operation. Investigation found a build-up of inhibitor on the cables and fairlead pressure seals. Power levers still difficult to move. Investigation continuing.Fokker F28 MK0100 AC power distribution system bracket faulty. SDR 510017451During replacement of a u/s transformer rectifier unit (TRU) the circuit breaker tripped and earth wire insulation started to burn. Investigation found faulty bonding on the TRU attachment brackets after painting.

47FLIGHT SAFETY AUSTRALIAIssue 94 September–October 2013

Fokker F28 MK0100 brake disintegrated. SDR 510017594LH main landing gear No.1 wheel locked due to disintegrated brake discs. Investigation continuing.Fokker F28 MK0100 Potable water system – pipe failed. SDR 510017463Galley 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 510017421LH 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 510017499Forward elevator transition cable worn and tension low. P/No: 503028555.

Saab SF340B Airfoil de-ice boot ruptured. SDR 510017430RH 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 510017568Landing gear selector valve wire worn through and short circuiting on hydraulic pipe.

AIRCRAFT BELOW 5700KG

Alpha Aviation R2160 Fuselage plates/skin cracked. SDR 510017455RH 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 510017566RH wing upper and lower spar caps P/Nos: 6057122001, 6057123001 and LH wing lower spar cap P/No: 60-57-124-001 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 | REGULARSService difficulty reports

Britton Norman BN2A20 Wing spar cap cracked. SDR 510017418LH 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 510017557LH 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.

Britton Norman BN2B20 Nacelle/pylon miso structure angle cracked. SDR 510017581LH 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 510017425RH main landing gear brake disc corroded.

Cessna 172N Engine air intake system arm worn. SDR 510017422Carburettor heat box valve arm worn and valve partly separated from shaft.

Cessna 172N Engine mount section – mount worn. SDR 510017424Engine mount rear cross tube worn due to mixture cable rubbing. Cessna 172N Landing gear attach fittings – loose rivets. SDR 510017423Nose landing gear lower support fitting rivets loose and working. Firewall slightly buckled. Cessna 172RG Elevator control system – bellcrank corroded. SDR 510017598Elevator bellcrank corroded in area where stop bolt contacts. Aircraft stored outside in a coastal environment. P/No: 05341221. TSN: 6631 hoursCessna 177B Nose landing gear strut/axle – oleo strut unserviceable. SDR 510017571Nose 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 hoursCessna 208B Power lever – condition lever fractured. SDR 510017528Engine fuel condition lever fractured through rudder control lock operating rod attachment bolt hole.P/No: C2995140101. TSN: 12443 hoursCessna 208 Landing gear position and warning system – proximity switch failed. SDR 510017515RH main landing gear proximity switch wire separated. Salt water entering switch and causing corrosion. Aircraft equipped with floats. P/No: 5801HAMLIN59135020.

49FLIGHT SAFETY AUSTRALIAIssue 94 September–October 2013

Cessna 402C Landing gear position and warning system – switches unserviceable. SDR 510017511Landing 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 510017438RH 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 510017450LH 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.

Gippsland Aeronautics GA8 Fuselage stabiliser attach fittings - doubler cracked. SDR 510017428RH horizontal stabiliser attachment fitting skin doubler cracked. P/No: GA8538021310. TSN: 7,045 hours

Kavanagh B400 Balloon load frame cracked. SDR 510017466Balloon load frame cracked adjacent to previous repair. P/No: LF148. TSN: 1,707 hours TSO: 1,707 hours

Pilatus PC12 Aircraft fuel distribution system – pipe unserviceable. SDR 510017607Fuel feed pipe leaking in area of RH undercarriage. Lower anti-collision wire LT8B18 rubbing and arcing on fuel pipe. P/No: 5282412173

Pilatus PC12 Trailing edge flap control system FCWU faulty. SDR 510017591Replacement 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 | REGULARSService difficulty reports

Piper PA28140 Control column section shaft corroded. SDR 510017520Pilot's control column shaft universal joint corroded and seized.

Piper PA31350 Elevator spar/rib – spar cracked. SDR 510017507RH elevator spar cracked at trim tab attachment. P/No: 40076000. TSN: 16333 hours

Swearingen SA227DC GPS antenna unserviceable. SDR 510017488GPS 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

Swearingen SA227DC Wheel seal unserviceable. SDR 510017461Nose wheel bearing seal u/s. P/No: 13600LA. TSN: 240 hours/307 cycles TSO: 240 hours/307 cycles

COMPONENTS

Simmonds Precision Products Inc. 10056000001 indicator incorrectly marked. SDR 510017478Fuel 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.

PISTONContinental TSIO520VB Exhaust turbocharger seal leaking. SDR 510017486RH turbocharger leaking. Rear oil seal had failed. Turbocharger had just been fitted and engine was being test run.

51FLIGHT SAFETY AUSTRALIAIssue 94 September–October 2013

Continental TSIO520N Reciprocating engine cylinder cracked and leaking. SDR 510017599RH 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

Lycoming IO540K1A5 Fuel control/reciprocating engines FCU leaking. SDR 510017565Fuel 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

Lycoming IO540E1B5 Reciprocating engine internal oil filter separated. SDR 510017583LH engine oil filter threaded tube broke away from adapter and filter separated.

Jabiru JABIRU2200B Reciprocating engine cylinder piston damaged. SDR 510017489No.1 cylinder piston destroyed and connecting rod bent. Exhaust valve misaligned. Suspect caused by failure of, or incorrectly fitted, piston pin circlip.

PROPELLER Hamilton Standard 14SF7 Propeller blade bearing damaged. SDR 510017573LH propeller No. 3 blade bearing damaged, allowing oil loss.

Hartzell HCF2YR1 Propeller governor unserviceable. SDR 510017613Propeller governor u/s. Top cover cracked and separating at bottom of lever housing. Investigation continuing. P/No: C210776A. TSN: 8829 hours TSO: 98 hoursMcCauley 3AF32C505 Propeller blade bearing cracked and corroded. SDR 510017615Propeller 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 hoursMcCauley 3FF32C501 Propeller spinner and bulkhead unserviceable. SDR 510017617Propeller spinner and bulkhead worn and damaged. Mounting holes elongated.

ROTORCRAFT

Agusta Bell A109E Ice and rain protection wiring splice damaged. SDR 510017602No. 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.

Agusta Westland AW139 Tail rotor control system - tube cracked. SDR 510017534Tail rotor pedal assembly tubes (4off) cracked. Found during inspection iaw BT 139-302.P/No: M01501M17245. TSN: 1,001 hoursBell 407 AC generator alternator PMA unserviceable. SDR 510017519Engine-driven permanent magnet alternator (PMA) drive sheared due to failed bearing.P/No: 90490052. TSN: 650 hoursBell 429 Cabin cooling system fan unserviceable. SDR 510017614Air-conditioning system condenser fan u/s. Investigation found wear in bushing preventing drive between motor and fan and allowing fan to freewheel and tips to rub. Found during inspection iaw Air Comm SL 263. P/No: S6063EC1. TSN: 467 hours

52 CONTENTS | ARTICLES | AIRWORTHINESS | REGULARSService difficulty reports

Eurocopter AS332L Main rotor gearbox filler cap loose and leaking. SDR 510017429Main gearbox oil filler cap loose and leaking and ‘O’ ring dislodged. Loss of gearbox oil. P/No: 706A34542007.

Eurocopter AS350B2 Main rotor gearbox thrust plate incorrect fit. SDR 510017622Main rotor gearbox epicyclic reduction gear thrust washer plate incorrectly installed. P/No: 350A32010010.

Eurocopter AS365N Fuselage window frame cracked. SDR 510017484LH canopy frame cracked.

Robinson R44 Engine noise suppressor muffler collapsed. SDR 510017626Exhaust muffler collapsed at tailpipe attachment. Found during inspection iaw AWB-78-001.P/No: C16932. TSN: 664 hoursRobinson R44 Engine/transmission coupling limit switch failed. SDR 510017529Engine 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

53FLIGHT SAFETY AUSTRALIAIssue 94 September–October 2013

Robinson R44 Main landing gear elbow cracked and corroded. SDR 510017441Landing 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

TURBINE ENGINESAllison 250C20B Turbine governor drive shaft failed. SDR 510017606Power turbine governor input shaft failed. Drive spline worn causing erroneous signals to FCU. Garrett TFE7312 Turbine engine compressor carbon seal leaking. SDR 510017497RH 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 510017505RH engine oil pump idler gear shaft sheared. Metal contamination of oil system.

PWA PT6A41 Turbine engine metal contamination. SDR 510017621LH engine oil pressure fluctuating followed by surge and shutdown. Initial investigation found metal in oil filter and on chip detector. P/No: PT6A41.

PWA PT6A67B Turbine engine reduction gearbox metal contamination. SDR 510017554Reduction 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 510017447No. 3 engine IP coupling splines worn beyond limits. Found during boroscope inspection iaw RB211-72-AG329.

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/

TO REPORT URGENT DEFECTS

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