40 CONTENTS | ARTICLES | AIRWORTHINESS | REGULARSService difficulty reports

22 March – 13 May 2013Note: Similar occurrence figures not included in this edition

Above 5700kgAirbus A320-231 Flight compartment window incorrect mod. SDR 510017168Cockpit sliding window seals incorrectly modified iaw AD 2013-0011 and SB A320-56-1015. P/No: NP16531211. TSN: 6892 hours/3228 cycles. Eight other similar defectsAirbus A320-232 Aileron control eLAC unserviceable. SDR 510017051No. 1 Elevator and aileron computer (ELAC) suspect faulty. P/No: 3945128209. TSN: 10,351 hours/5782 cycles.Airbus A320-232 Hydraulic indicating system – pressure switch suspect faulty. SDR 510017048Elevator and aileron computer (ELAC) fault warning. Investigation found the yellow hydraulic system pressure switch (FIN3151GN) suspect faulty. Switch replaced and system tested serviceable. P/No: 4502310000.Airbus A320-232 Wheel unserviceable. SDR 510017218No. 2 main wheel unserviceable. Investigation found wheel bearing housing collapsed. P/No: 21684. TSN: 1280 hours/639 cycles.

Airbus A321-231 Air distribution exhaust fan failed. SDR 510017184Electrical burning smell in cockpit and forward cabin. Investigation found avionics bay extraction fan had failed.Airbus A330-243 Hydraulic system – check valves loose. SDR 510016985Blue and yellow hydraulic system check valves loose with red markings misaligned. Found during inspection iaw AD 2012-0244 and SB A330-29-3111.Airbus A380-842 APU shroud damaged. SDR 510017195APU turbine air shroud punctured/holed allowing air to escape. Investigation of surrounding area found nil damage. TSN and TSO: 4102 hours.

Airbus A380-842 Flight compartment window shattered. SDR 510016926First officer's No. 2 sliding window outer pane shattered. P/No: SGSA380411. TSN and TSO: 10,634 hours.

AMD Falcon 200eX Fuselage tail cone damaged. SDR 510017214T5 fuselage section (tail area) damaged when aircraft was moved with mechanic’s ladder extended. Damage to skin in structural frames.

ATR-72-212A Air conditioning system odour. SDR 510016930Brief burning smell in cabin in area of row 4. Extensive investigation found no definitive cause for the smell and it has not returned since.

41FLIGHT SAFETY AUSTRALIAIssue 94 September–October 2013

ATR-72-212A Air distribution system – duct distorted. SDR 510016970Overboard avionics vent ducts P/Nos: S21283310000 and S2128314100400 under cargo floor panel partially collapsed. P/No: S21283310000. TSN: 3902 hours/3758 cycles.

bAC 146-200 escape slide – hose failed. SDR 510017298Rear passenger door emergency slide failed to deploy and emergency lights failed to activate. Investigation found hose P/No: AE705782-1 defective. TSN: 311 hours/319 cycles.bAC 146-300 Air conditioning system odour. SDR 510017165Oil smell in aircraft. Investigation iaw SB 21-150 and AD/Bae146/86 found no definitive cause.beech 300C Fuel valve unserviceable. SDR 510016971LH fuel system anti-syphon check valve u/s. Valve found stuck open. TSN: 1500 hours.boeing 717-200 APU odour. SDR 510016986Smells in cabin. APU suspected as engines had been shut down. Investigation found oil contamination of APU resulting in replacement. Suspect APU carbon seal failure.P/No: 4502440. TSN: 19,157 hours/19,513 cycles. TSO: 3233 hours/2926 cycles.boeing 717-200 Hydraulic pump failed. SDR 510017065RH engine-driven hydraulic pump failed. P/No: 66180. TSN: 20,045 hours/12,639 cycles. TSO: 20,045 hours/12,639 cycles.boeing 717-200 Flight compartment windshield arced. SDR 510017371First officer's windshield arcing from electrical connector when anti-ice selected.P/No: 5912290508. TSN and TSO: 13,595 hours/8414 cycles/64 months.

boeing 737-7bK Stall warning system – sensor unserviceable. SDR 510017131LH Angle of attack (AOA) sensor u/s. P/No: 0861FL1. TSN: 2055 hours/1511 cycles.boeing 737-838 battery thermal runaway. SDR 510017006Acid leaking from battery caused corrosion of the E/E cooling duct in the cargo area.boeing 737-838 elevator control system – actuator iced. SDR 510017192Elevators stiff in operation due to actuator icing.boeing 737-838 Fuel indicating warning system suspect faulty. SDR 510016968Fuel pump fault indications on master caution panel. Investigation found no faults with fuel pump indication system.boeing 737-838 Fuel wiring connector failed test. SDR 510017290RH fuel tank wiring connector P/No: D11314 failed resistance check. Found during inspection iaw AD 2008-10-10.boeing 737-838 Landing gear tyre partially separated. SDR 510017122LH main landing gear inboard tyre tread separated. Approximately 1.2m (4ft) of tread centre section missing. Investigation found nil damage to aircraft.boeing 737-838 Wheel bolt sheared. SDR 510017005No. 4 main landing gear wheel tiebolt sheared. Nut and threaded end of bolt missing.P/No: 277A6000204. TSN: 14,063 hours. TSO: 202 hours.boeing 737-8Fe Fuel storage – access panel leaking. SDR 510017174RH wing fuel tank access panel 632AB leaking. P/No: 65C330928. TSN: 3125 hours/1325 cycles.boeing 737-8Fe Fuel storage – seal deteriorated. SDR 510017164LH wing tank panel 533B leaking due to disintegrated seal. P/No: 110A01141.boeing 737-8Fe Stall warning system – sensor unserviceable. SDR 510016935No. 1 Angle of attack (AOA) sensor u/s. P/No: 0861FL1. TSN: 41,146 hours/22,853 cycles.boeing 737-8Q8 Landing gear brake system – brake fuse failed. SDR 510017202LH outboard brake hydraulic fuse failed. Reset lever separated from housing along with a significant hydraulic leak. Investigation found the reset lever assembly retaining bolts had failed. P/No: 280411. TSN: 8743 hours/4761 cycles.boeing 767-338eR APU suspect faulty. SDR 510017297Electrical smell in cabin followed by APU auto shutdown. Initial investigation found APU chip detector heavily contaminated. Investigation continuing. P/No: 380029812. TSN: 78,275 hours. TSO: 4528 hours.

42 CONTENTS | ARTICLES | AIRWORTHINESS | REGULARSService difficulty reports

boeing 767-338eR Fuel wiring AD requirement. SDR 510017324Fuel boost pump wires defective. Found during inspection iaw AD-B767-123 and SB 767-28A0053. boeing 737-8Q8 Passenger station equipment system – PSU incorrect mod. SDR 510017113Passenger service unit (PSU) did not have SB 737-25-1545 correctly embodied. Paperwork from supply vendor stated SB had been carried out. P/No: 417N30111414B.boeing 767-338eR APU smoke/fumes. SDR 510016987Oil smell and smoke in cockpit. Investigation found oil contamination of APU. APU changed. Investigation continuing.boeing 767-338eR Fuel wiring conduit faulty. SDR 510017183LH wing fuel pump conduits damaged. Electrical harnesses serviceable with nil damage. Found during inspection iaw AD/767/123. P/No: 015T087230.boeing 777-3ZGeR Leading edge slat actuator sheared drive shaft. SDR 510017187RH wing leading edge Krueger flap actuator input shaft sheared. P/No: 256W23103. TSN: 20,874 hours/1681 cycles.bombardier DHC8-102 brake housing cracked. SDR 510016963Brake housing cylinder bore had a crack approximately 24mm (0.94in) long. Found during fluorescent penetrant inspection. P/No: 214665. bombardier DHC8-102 engine mount section bracket cracked. SDR 510017068Front top engine mount bracket had a crack approximately 17mm (0.67in) long. Found during fluorescent inspection. P/No: LM43163. bombardier DHC8-315 Airfoil de-ice boot loose. SDR 510017224Elevator leading edge de-icer boot coming loose due to suspected adhesive failure. Boot still inflates. bombardier DHC8-102 Aileron control cable low tension. SDR 510017266Roll disconnect system faulty. Investigation found insufficient tension in cable and clutch contaminated with grease.bombardier DHC8-315 Flight management system (FMS) smoke/fumes. SDR 510017359Smoke from FMS caused flight crew to don oxygen masks.bombardier DHC8-315 Windshield overheated. SDR 510017301Captain's side windshield cracked in several places with a small amount of smoke emanating from some of the cracks. No smoke when windshield heating turned off. Suspect faulty de-icing system. Investigation found no definitive fault with the heating system, which tested serviceable.

bombardier DHC8-402 Pneumatic distribution system odour. SDR 510017336Dusty odour in galley and smoke alarm heard in toilet. Investigation found odour associated with bleed air from the APU.embraer eMb-120 Fuel indicator illegal modification. SDR 510016972Fuel flow indicator initially u/s because moisture on the dial face caused it to delaminate. Indicator had been illegally modified to indicate kilograms/hour instead of pounds/hour. Inspection found non-original sticker instead of original dial face. ID plate also altered. P/No: 946441.

embraer eRJ-190-100 elevator control system – actuator leaking. SDR 510017209RH inboard elevator power control unit (PCU) leaking beyond limits. P/No: 4161001001. TSN: 6149 hours/4098 cycles.embraer eRJ-190-100 elevator control system – disconnect device faulty. SDR 510017052Control column notchy in operation. Investigation found a faulty elevator disconnect device. P/No: 17024298407. TSN: 9025 hours/6046 cycles.embraer eRJ-190-100 Flight compartment windshield cracked. SDR 510016978Outer layer of captain's windshield cracked and partially missing. P/No: NP18730113. TSN: 12,701 hours/8524 cycles.

43FLIGHT SAFETY AUSTRALIAIssue 94 September–October 2013

embraer eRJ-190-100 Fuselage – main floor beam corroded. SDR 510017081Centre fuselage floor beam corroded between frames 86 and 89 on RH side.P/No: 17065669004. TSN: 9866 hours/6129 cycles. One other similar defectembraer eRJ-190-100 Fuselage, miscellaneous structure – fitting corroded. SDR 510017084Lower door seal rest fittings P/Nos: 170-85492-403, 170-85493-403 and 170-85251-401 corroded. TSN: 9866 hours/6129 cycles.embraer eRJ-190-100 Hydraulic pump failed. SDR 510017204No. 2 engine-driven hydraulic pump failed. Metal found in case drain filter. P/No: 5116404. TSN: 6398 hours/4450 cycles.embraer eRJ-190-100 Wing skin cracked. SDR 510017086LH and RH wing upper skins P/Nos: 190-33013-425 and 190-33014-425 cracked. LH skin had two cracks between ribs 14 and 16 and ribs 15 and 17. RH wing skin cracked between ribs 18 and 19 aft of rear spar. Cracks approximately 85mm (3.34in) long.P/No: 19033013425. TSN: 9866 hours/6129 cycles.embraer eRJ-190-100 Wing winglet corroded. SDR 510017083LH and RH winglet assemblies P/Nos: 190-34001-421 and 190-34001-422 upper and lower surfaces corroded. TSN: 9866 hours/6129 cycles.embraer eRJ-190-100 extinguisher discharged. SDR 510017274Forward toilet automatic fire extinguisher pressure gauge indicating empty. Investigation found fire extinguisher had discharged, without any indications of heat.Solder plug protruding approximately 3mm (0.118in) from discharge tube.P/No: BA230941. TSN: 13,882 hours/9693 cycles.embraer eRJ-190-100 Fuselage floor beam corroded. SDR 510017321Fuselage floor beam between LH frames 86 and 89 had level 2 corrosion.P/No: 17065669003. TSN and TSO: 14,663 hours/9755 cycles/9755 landings/66 months. Fokker F27 MK50 Main landing gear oleo strut failed. SDR 510017242LH main landing gear strut leaking. Metallic particles found in the lower strut came from lower piston rod and piston rod end skirt shim. Further damage at end stop skirt and sleeve. TSN: 6404 hours/5395 cycles.Fokker F28 MK0100 Fuselage attach fitting cracked. SDR 510016944Speed brake hinge support cracked on all four corner flanges. Found during inspection iaw SBF100-53-113. P/No: A38004421.

Fokker F28 MK0100 Fuselage bulkhead angle cracked. SDR 510017221Fuselage forward pressure bulkhead angle to fuselage skin cracked on LH and RH sides. Crack on LH side approx. 8mm (0.314in) long. Crack on RH side approx. 140mm (5.5in) long. Found in NDT inspection. P/No: D22213702.Fokker F28 MK0100 Fuselage bulkhead cracked. SDR 510016941Rear pressure bulkhead had three horizontal cracks between beams XI and X. Found during inspection iaw SBF100-53-120.Fokker F28 MK0100 Fuselage bulkhead cracked. SDR 510017123Forward pressure bulkhead skin cracked above the mid centre of support IV. Crack approx. 53mm (2.08in) long. Found during NDT inspection. Fokker F28 MK070 Cabin pressure controller unserviceable. SDR 510017110Controller failed to release pressure, preventing cabin door from opening.Fokker F28 MK0100 Fuselage cover cracked. SDR 510017370Nose landing gear bay top cover cracked in numerous areas. Found during eddy current NDI. Fokker F28 MK0100 Landing gear steering cable distorted. SDR 510017300Nosewheel steering system outboard crossover cable kinked, tiller input drum worn and bearings stiff. Investigation continuing.Israel 1124 Landing gear failed to retract. SDR 510017339LH main landing gear failed to fully retract.Raytheon 850XP AC alternator drive shaft sheared. SDR 510016979LH AC alternator drive shaft sheared. Metal debris in lower cowl. Engine gearbox drive serviceable. TSN: 2471 hours/1891 cycles/1891 landings/83 months.Saab SF340b Fuel wiring conduit unserviceable. SDR 510017134LH wing tank refuel shutoff valve wiring conduit worn through in area of contact with a rubber grommet. Found during investigation iaw AD/SF340/104 and SB340-28-11. P/No: 7228308563. One similar occurrence.

44 CONTENTS | ARTICLES | AIRWORTHINESS | REGULARSService difficulty reports

Saab SF340b Fire detector suspect faulty. SDR 510017312RH tailpipe hot detector suspect faulty. Investigation continuing. P/No: 1734362450.

AIRCRAFT beLoW 5700kgvans Rv-6 Rudder control system arm failed. SDR 510016955RH rudder pedal support arm failed. Aircraft ran off runway, damaging LH wheel spat during engine runup. TSN: 376 hours.

beech 200 Horizontal stabilizer spar cap corroded. SDR 510017098Horizontal stabiliser spar caps P/Nos: 1016200143 and 1016200144 had exfoliation corrosion. Found during boroscope inspection. TSN: 18,903 hours/16,284 cycles.

beech 36 Wing spar corroded. SDR 510017032Rear carry through spar forward and aft cover plates had exfoliation corrosion. Found during inspection iaw AD/Beech35/74 Amdt1. P/No: 364000168.beech b350 engine mount section bracket cracked. SDR 510016946LH engine mount truss inboard upper cowling mount bracket cracked next to weld. P/No: 10191012253.beech G58 Trailing edge flap actuator – gearbox loose and leaking. SDR 510016928Flap drive gearbox leaking in area of RH output shaft. Large quantity of metal particles found under the RH cable retainer which was rubbing on the cable housing. Gearbox found to be misaligned, with loose mounting bolts. LH cable retainer not locked and the LH cable key corroded and seized in the gearbox drive. Input drive appeared to be shortened by approx. 3.175mm (0.125in), with the drive coupling contacting the gearbox housing. P/No: D160003. TSN: 664 hours.

45FLIGHT SAFETY AUSTRALIAIssue 94 September–October 2013

Cessna 172G elevator control system bracket broken. SDR 510017185Forward elevator bellcrank mount bracket broken. P/No: 05130633. TSN: 5340 hours.

Cessna 172R Aileron control system cable frayed. SDR 510016929LH aileron carry-through cable worn with broken strands at fairlead at WS 71.125. P/No: 0510105364. TSN: 332 hours.

Cessna 172R Aileron cable worn and damaged. SDR 510017265LH aileron balance cable worn and frayed at WS73 by rib chafe strip. P/No: 0510105364. TSN: 614 hours.Cessna 182L Landing gear attach fittings support cracked. SDR 510017137RH outboard main landing gear support fitting cracked. P/No: 07416032. TSN: 6362 hours.

Cessna 208b Fuselage main, attach fittings bracket cracked. SDR 510016954Centre wing section flap transmission attachment bracket cracked. P/No: 26111441. TSN: 3100 hours/94 months.

Cessna 210L elevator spar cracked. SDR 510017095RH elevator rear spar cracked approximately 89mm (3.5in) inboard of the elevator trim tab cutout. Found during inspection iaw SID 55-10-01 (aircraft serial number not in range covered by this SID. P/No: 12346384. TSN: 7368 hours/444 months. Cessna A37b Wing spar cap corroded. SDR 510016943RH wing lower spar cap corroded in numerous areas. Investigation also found that areas of corrosion had previously been mechanically blended which is not permitted iaw structural repair manual TO 1A-378-3. P/No: 41223964.Cessna U206C Aileron control system bearing seized. SDR 510017179RH aileron rodend bearing seized. Rodend threaded section broken aft of locknut, causing disconnection of aileron control rod. Aircraft stored in the open in a coastal environment. P/No: 18204.Cessna U206G Rudder control system arm corroded. SDR 510017073Pilot's rudder pedal arm corroded (rusted) internally. Bolt P/No: AN311A completely rusted through and arm only secured to the torque tube by rust. Rudder bar had only about 33 per cent of wall thickness remaining. P/No: 0411307.

46 CONTENTS | ARTICLES | AIRWORTHINESS | REGULARSService difficulty reports

Cessna 402b Wing attach fitting support cracked. SDR 510017311LH main fuel tank aft mount and wing rear spar cracked. Investigation continuing.Cirrus SR22 Aircraft structural damage. SDR 510017022Aircraft parked next to an aircraft destroyed by fire. Investigation found numerous areas of heat damage, including the RH wingtip, RH cabin door windows, rear windows and doors. Composite material had been exposed to heat above manufacturer’s limits, causing its structural integrity to be compromised. DHAv DHC2MK1 Main landing gear strut cracked and corroded. SDR 510017281RH rear float strut cracked after previous repair. Suspect caused by salt water corrosion. P/No: 58S9242. TSO: 36 months.Gippsland GA8 Stabiliser attach fittings doubler cracked. SDR 510017277LH and RH horizontal stabiliser pivot bracket skin doublers P/Nos: GA8538021309 and GA8538021310 cracked. TSN: 3766 hours. One other similar defect.

Gippsland GA200C Main landing gear failed. SDR 510017106LH main landing gear leg failed at weld. Propeller and LH wing hit the ground. Subsequent MPI investigation of RH main landing gear leg found cracking in butt weld between upper and lower doubler straps. TSN: 2357 hours.

Gulfstream 500S Wing spar cap corroded. SDR 510017127LH wing outboard lower spar cap corroded at WSTA 98.5. TSN: 8113 hours.Gulfstream 500S Landing gear clevis failed. SDR 510017303Aircraft lost altitude and contacted the runway on partially retracted landing gear, causing superficial damage to the belly skin. Landing gear then extended using the emergency backup and aircraft landed safely. RH main landing gear actuator clevis broken and a hydraulic leak in the baggage locker. Investigation continuing. TSO: 2200 hours.Mooney M20J Wing spar cap corroded. SDR 510017019LH and RH wing upper spar caps P/Nos: 210001007 (LH) and 21001008 (RH) badly corroded on lower faces. One rivet tail also missing from RH spar cap. TSN: 5196 hours.PAC 750XL Nose landing gear strut piston corroded. SDR 510017020Nose landing gear piston leg lower area corroded. P/No: 11400092.

47FLIGHT SAFETY AUSTRALIAIssue 94 September–October 2013

Pilatus PC12 Hydraulic pump relay unserviceable. SDR 510017285Main hydraulic pump contactor relay failed. Pump contactor 100 amp coil short circuited. P/No: 9740926112.Piper PA-28-151 Stabiliser control system terminal corroded. SDR 510016973Stabiliser control cables P/Nos: 62701112 and 62701113 corroded on turnbuckle terminal ends.

Piper PA-28-180 Stabiliser control system terminal corroded. SDR 510017097Stabilator control cable swaged terminal ends had fine corrosion pitting. P/Nos: MC62701010, MC62701011, MC62701012 and MC62701013. Found during inspection iaw AD 2013-02-13. TSN: 6286 hours.Piper PA-28R-201 Wing spar corroded. SDR 510017262Wing rear spar P/No: 62054 and spar plate P/No: 62056 corroded. Found during inspection iaw AD/ PA28/40. TSN: 10,288 hours.Piper PA-32-300 Aileron control system restricted. SDR 510017041Aileron system jamming when moved to the right. Full movement when aileron moved to the left.Piper PA-32-300 Aileron control system cable broken. SDR 510017066Aileron control system restricted in operation. When controls were forced the cable bridle failed. P/No: 753980. TSN: 5761 hours.

Piper PA-44-180 Cabin heating system pressure switch faulty. SDR 510017074Cabin combustion heater differential pressure switch faulty. Found during inspection iaw AD/aircon/12 Amdt 3. P/No: 94E423. TSN: 405 hours.

Piper PA-44-180 Fuel boost pump coupling cracked and leaking. SDR 510017064RH engine fuel pump coupling cracked and leaking. P/No: 556406. TSN: 478 hours.

Socata Tb20 Trinidad Wing spar cap corroded. SDR 510017235LH wing lower spar cap corroded between ribs N3 and N4. TSN: 3346 hours/276 months.

48Socata Tb20 Trinidad Landing gear bearing cracked. SDR 510017275LH wing main landing gear attachment bearing cracked in radius. Found during inspection iaw AD/ TB20/32 Amdt 1. P/No: TB2043013000. TSN: 3939 hours/5899 landings/348 months. One other similar defectSwearingen SA227AC brake contaminated. SDR 510017091RH main landing gear inboard brake contaminated with oil preventing adequate braking and allowing the aircraft to swerve off the runway and become bogged in soft ground. Stone damage to all four LH propeller blades. Swearingen SA227AC elevator structure hinge corroded. SDR 510017034RH elevator outboard hinge assembly had exfoliation corrosion near bearing. P/No: 2743019009.

Swearingen SA227DC DC power distribution system current limiter overheated. SDR 510016933Smoke coming from non-essential bus. Investigation found LH current limiter terminal overheated. Suspect caused by age and oxidation. P/No: ANL225. Swearingen SA227DC Trailing edge flap control system faulty. SDR 510017282Flap system suspect faulty. Aircraft rolls right when flaps retracted and rolls left on flap extension. Investigation found excessive freeplay in the flap system, and RH flap actuator leaking. TSN: 20,571 hours/22,613 cycles.

CoMPoNeNTSFrame cracked and corroded. SDR 510017154Engine LP fan frame support assembly cracked at top centre. P/No: 206301027. TSN: 21,230 hours/15,954 cycles. TSO: 6104 hours/3469 cycles.

Kavanagh b400 balloon piston out of tolerance. SDR 510017373Balloon pilot light reduced in size due to loss of flow and pressure. Liquid pilot light piston assembly out of tolerance. TSN: 121 hours.Rosemount Inc. NA sensor SUP. SDR 510017039Total air temperature (TAT) sensor suspect unapproved part (SUP). Inspection on receipt found the serial number had been etched out and a new serial number stamped into the unit. P/No: 102LA2AG.

PISToNContinental Io360C Reciprocating engine rear section bearing failed. SDR 510016965Rear engine starter adapter worm drive bearing failed. Metal contamination of oil system with metal particle lodged under oil pressure relief valve seat. P/No: 641368.Continental Io360D Magneto cracked. SDR 510017200Front engine LH magneto attachment housing flange cracked. Manufacturing defect found in the casting when magneto removed. P/No: 107902016. TSN: 1488 hours.Continental Io360D Reciprocating engine rear section gear stripped. SDR 510016927Gear teeth found in sump during oil change. Six teeth stripped from fuel pump and governor drive gear. P/No: 629602.

Continental GTSIo520M Magneto failed. SDR 510017348LH engine LH magneto internal failure. Distributor block bearing failed causing distributor gear teeth to break. P/No: BL3492204. TSO: 290 hours.Continental Io520C Magneto failed. SDR 510017190RH engine LH magneto failed internally after only 16.1 hours TSO.

CONTENTS | ARTICLES | AIRWORTHINESS | REGULARSService difficulty reports

49FLIGHT SAFETY AUSTRALIAIssue 94 September–October 2013

Continental Io520F Reciprocating engine valve lifter pitted. SDR 510017278No. 2 cylinder exhaust valve hydraulic lifter badly eroded and pitted. P/No: 646277. TSN: 1124 hours.

Continental Io520M Cylinder section piston ring faulty. SDR 510017332LH engine No. 4 cylinder top compression piston ring faulty due to delamination of chrome plating. Top compression rings on all except No. 1 cylinder in a similar condition. P/No: 654716. TSN and TSO: 323 hours. Continental o470R engine ignition switch unserviceable. SDR 510017139LH magneto remained live when key removed. P/No: 101266901B.Jabiru 2200A Reciprocating engine cylinder section pushrod worn and damaged. SDR 510017124Valve pushrods worn and damaged. Foreign-registered aircraft. TSN: 18 hours.

Jabiru 2200b Reciprocating engine power section bolt broken. SDR 510017152One through bolt and one holddown stud broken on No. 4 cylinder. P/No: 4292044542910445. TSN: 1155 hours. TSO: 177 hours.Lycoming Io540e1b5 Reciprocating engine piston fire. SDR 510017055LH engine had a suspected fire on startup. Fire extinguisher activated. Flames due to attempted start of a flooded engine. Nil damage found.

Lycoming Io540e1b5 Reciprocating engine power section stud failed. SDR 510017004No. 4 cylinder holddown studs failed. Cylinder only held on by through bolts.Lycoming Io540K1A5 engine fuel pump unserviceable. SDR 510016920Engine-driven fuel pump low pressure after only operating for only 90 hours after repair. P/No: 201F5003. TSN: 90 hours.Lycoming o360A1G6 Reciprocating engine power section tappet body spalled. SDR 510017161Metal contamination of oil system. No. 1 and No. 3 cylinder inlet tappet bodies and No. 2 and No. 4 cylinder exhaust tappet bodies spalled. P/No: 15B26064. TSN: 485 hours.Lycoming o360J2A Magneto/distributor bushing loose. SDR 510017177Block bushing loose, resulting in timing problems. P/No: 106006141. TSO: 200 hours.Lycoming o360J2A Reciprocating engine cylinder exhaust valve stuck. SDR 510017070No. 2 cylinder exhaust valve stuck in valve guide P/No: 74230. TSN: 565 hours.Lycoming o540F1b5 Reciprocating engine cylinder failed. SDR 510017109No. 2 exhaust valve and guide failed and separated from cylinder, taking some of the cylinder with it. No. 2 exhaust pushrod bent. Metal contamination of engine. TSO: 802 hours.

50 CONTENTS | ARTICLES | AIRWORTHINESS | REGULARSService difficulty reports

Lycoming TIo540A2C Magneto distributor damaged. SDR 510017322RH engine RH magneto distributor block faulty. Distributor block installed at factory overhaul. Fish paper strip P/No: 10349326 obscuring the distributor gear assembly. Wedges P/No: 10349219 securing coil were bent and the bush was loose in the distributor block, allowing the electrode to contact the HT terminals. Washer P/No: 10349511 also worn. TSO: 102 hours. One other similar defect.

Lycoming TIo540J2bD Reciprocating engine oil system adapter leaking. SDR 510017333LH engine oil filter adapter plate seal split and leaking. P/No: O6B23072. TSN and TSO: 194 hours.

PRoPeLLeRHartzell HCb4MP3C Propeller governor bearing failed. SDR 510017289LH engine propeller governor flyweight bearing collapsed, releasing balls. Three balls found in the reduction gearbox. P/No: NK. TSN: 639 hours/275 cycles/284 landings/25 months.

RoToRCRAFTAgusta Westland AW139 Main hydraulic system shutoff valve cracked and leaking. SDR 510017225Hydraulic shutoff valve cracked and leaking at fitting housing. P/No: 3G2910V00231. TSN: 2780 hours.

Agusta Westland AW139 Main main rotor blade suspect faulty. SDR 510017021Main rotor blade leading edge bolt had a 2mm (0.078in) gap between the washer and tension link. P/No: 3G6210A00131. TSN: 463 hours/753 cycles.bell 206b3 Tail rotor drive shaft drive shaft cracked. SDR 510017038Tail rotor drive shaft Thomas coupling cracked. P/No: 206040385105. TSN and TSO: 2690 hours. bell 206b Main rotor gearbox case faulty manufacture. SDR 510016950Main transmission duplex bearing sleeve had no oil gallery. Duplex bearing had a blueish discolouring. P/No: 20604000225. TSN: 7000 hours.

51FLIGHT SAFETY AUSTRALIAIssue 94 September–October 2013

bell 412 engine drain hose suspect faulty. SDR 510017233RH engine automatic fuel control unit (AFCU) drain hose suspect faulty, causing fuel to flow from the drain hole and contaminate the AFCU bearings. P/No: 70009F000Y300A475C61NSX. TSN: 4626 hours/168 months.bell 412 Main rotor contaminated – metal. SDR 510017148Main transmission chip detector illuminated. Investigation found an insignificant metallic deposit. P/No: 412040004109. TSN: 5207 hours. TSO: 403 hours.bell 412 Non-standard equipment system screw cracked. SDR 510017181Rescue hoist cable to drum attachment setscrews (2off) cracked, preventing screws from locking the cable into the drum and allowing the cable to separate from the drum during testing of full cable extension. P/No: NAS1081C3A5L. TSN: 20 hours/365 cycles.

bell 412 Pitot/static anti-ice system vent burnt. SDR 510017087Electrical burning smell in cabin. Co-pilot's lower heated pitot static vent burnt and smouldering. P/No: A02221.

bell 412 Fuselage attach bolt SUP. SDR 510017273Support beam assembly attachment bolt suspect unapproved part (SUP). Bolt found to have numerous damage marks when received. Further inspection found a discrepancy in part number marking. P/No: 604028001 identification on the outer plastic bag was correct for the ordered part, but marking on the inner plastic bag was P/No: 437000926, stating that it had been removed serviceable from another aircraft. Investigation could find no relationship between the two different part numbers. P/No: 604028001.

52 CONTENTS | ARTICLES | AIRWORTHINESS | REGULARSService difficulty reports

bell 412 Tail rotor blade cracked. SDR 510017357Tail rotor blade tip crack over 2.03mm (0.080in) deep. P/No: 212010750133. TSN: 2750 hours.bell 429 Fuselage skin fastener damaged. SDR 510017352Tail rotor driveshaft forward fairing Dzus fastener receptacle partially missing. Spring found in excess grease from tail rotor hangar bearing. Evidence of contact with tail rotor driveshaft. P/No: 50008R2C.

enstrom 280FX Rotorcraft tail boom support cracked. SDR 510017186Horizontal stabiliser external support brackets cracked. Support blocks also cracked with secondary damage to support spar and frame. TSN: 1588 hours/336 months. TSO: 1588 hours/336 months.

eurocopter AS332L engine indicating wiring worn and damaged. SDR 510017088No. 1 engine chip detector light illuminated. Wire between the amber PCB and caution warning panel worn. P/No: 1FW5013F.eurocopter AS332L Fuselage proximity sensor unserviceable. SDR 510017043Sliding cowl proximity sensor u/s. P/No: 704A37714005.eurocopter AS332L Tail rotor control system turnbuckle corroded. SDR 510017191Tail rotor control system turnbuckle corroded. Found during inspection iaw AD 2013-0081 and ASB AS332-05.00.95. P/No: 330A27503120.eurocopter AS350b2 Tail rotor control system PCL faulty manufacture. SDR 510017232Tail rotor pitch control rods (5off) u/s due to elastomeric bearings damaged or poorly fitted. Control rods were new. Defects found when they were removed from the original sealed packages to be fitted. P/No: 350A33214501.eurocopter AS350b3 Fuselage keel beam corroded. SDR 510017049LH fuselage keel beam corroded in area of second bolt hole from the forward end. P/No: Not listed in IPC. TSN: 3313 hours.

53FLIGHT SAFETY AUSTRALIAIssue 94 September–October 2013

eurocopter AS350b Fuselage fittings crossbeam cracked. SDR 510016948Main transmission attachment cross beam cracked. Found during replacement inspection iaw AD/Ecureuil/ 55 and SB 63-00-07. P/No: 350A38101832. TSN: 6064 hours/31,080 landings/289 months.

eurocopter AS365N Tail rotor control system actuator worn. SDR 510017002Yaw control actuator faulty. P/No: 41800478034.eurocopter bK117C2 Mixture control lever corroded. SDR 510017309Engine N2 control lever had severe exfoliation corrosion. Found during inspection iaw ASB MBBBK117C-2-76A-005. P/No: B761K2202101. TSN: 1745 hours/4886 cycles. One other similar defect

eurocopter eC225LP Fuel storage pipe cracked. SDR 510017189RH sponson pressure refuelling pipe from pressure connector cracked at swaged end fitting. P/No: 70434415266.

Robinson R22 beta cooling fan cracked. SDR 510017030Cooling fan hub cracked lengthways. Crack hidden by securing nut and washer and only found when fan removed. Suspect fan came from a faulty batch. P/No: B1741. TSN: 1178 hours.

Robinson R44 Main rotor blade debonded. SDR 510017196Main rotor blade leading edge upper skin debonding from D spar. P/No: C0167. TSN: 1,17 hours/25 months.Sikorsky S76C Main rotor head bearing cap delaminated. SDR 510016995Main rotor spindle bearing elastomer delaminated and separated from base plate. P/No: SB7003102SNB01308481. TSN: 806 hours.

54 CONTENTS | ARTICLES | AIRWORTHINESS | REGULARSService difficulty reports

Sikorsky S76C Rotorcraft tail boom support cracked. SDR 510016975Horizontal stabiliser support fitting cracked. P/No: 7620924004049. TSN: 13,000 hours/73,272 cycles/73,272 landings.

TURbINe eNGINeSGe CF680C2 Turbine disc eroded. SDR 510016956No.4 engine HPT stage 1 turbine disc heavily eroded in the armpit radius. Machining repair failed to remove pitting corrosion. Found during shop visit and inspection iaw AD/CF6/71. P/No: 1531M84G12. TSN and TSO: 43,832 hours. Ge CFM563C Thrust reverser slider failed. SDR 510017119RH engine thrust reverser inboard sleeve upper forward slide section failed. Area of failure approx. 88.9mm by 19mm (3.5in by 0.75in). Liberated section was trapped within thrust reverser. P/No: 315A170163A. TSN: 57,843 hours. TSO: 3,400 hours. Ge CFM567b Turbine engine leaking. SDR 510017130No. 1 engine oil leak. Oil found on spinner, fan blade platforms, fan blades and in booster. Ge CFM567b Fuel heat exchanger leaking. SDR 510016947No. 2 engine fuel leak from the fuel/oil heat exchanger inlet pipe connection. Three of four threaded inserts for securing the fuel pipe to the heat exchanger had migrated out of the heat exchanger body. P/No: 118411933. TSN and TSO: 17,499 hours. Ge CFM567b engine starter clamp failed. SDR 510017261No. 2 engine starter motor retaining clamp failed, allowing the starter to migrate and causing loss of engine oil.

IAe v2533A5 engine fuel distribution filter FoD. SDR 510016959No. 2 engine failed to reach target speeds during engine change ground run. Investigation found FOD to fuel HP pump inlet filter. Blank from the fuel-cooled oil cooler (FCOC) outlet had travelled to the filter.Lycoming ALF5071F Turbine engine compressor section frame cracked and corroded. SDR 510017154Engine LP fan frame support assembly cracked at top centre. P/No: 206301027. TSN: 21,230 hours/15,954 cycles. TSO: 6104 hours/3469 cycles.Lycoming LTS101750b1 Turbine engine compressor section carbon seal leaking. SDR 510016938Smoke in cockpit from area of heater system. Suspect faulty aircycle machine (ACM). No. 1 engine carbon seal leaking. P/No: 430404701.PWA PT6A114A Fuel control unit contaminated. SDR 510017076Engine fuel control unit (FCU) replaced due to erratic operation. Pa bleed in the P3 housing contaminated and restricted by FOD (a piece of cotton from a cotton bud). P/No: 32448974. TSO: 1073 hours/1236 cycles/12 months.PWA PT6A60A Fuel heater case cracked and leaking. SDR 510016981RH engine fuel/oil heater case cracked in weld area. TSO: 701 hours/612 cycles/13 months.

PWA PT6A65b Turbine blade cracked. SDR 510016991During fuel nozzle replacement, additional inspections found turbine blades (3off) with suspected cracks. Stator outer ring also cracked beyond limits. Stator housing floating grommets also cracked beyond limits. TSN: 21,605 hours/29,373 cycles. TSO: 2651 hours.

55FLIGHT SAFETY AUSTRALIAIssue 94 September–October 2013

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

CALL: 131 757 FAX: 02 6217 1920

Turbomeca Arriel 1S Turbine engine failed. SDR 510017246No. 2 engine failed during take-off. Initial investigation found compressor blades damaged severely from tip rub and difficult to turn. All magnetic plugs contaminated with debris. Power turbine noisy, with grinding noise heard when turned. Outlet diffuser had multiple cracks around oil and vent line. Free turbine blades have impact damage, sections of the trailing edge tips damaged, vent lines and T5 probes broken. Investigation continuing. P/No: 0292005250. TSN: 8812 hours/11,311 cycles. TSO: 984 hours/1150 cycles.

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