SDR 510022893 | Grob G115C2 Elevator control system—seal damaged. The right hand elevator Teflon gap seal was found damaged after the instructor returned to base because of the need for excessive back pressure on the elevator after conducting an unusual recovery lesson with a student. After return to the hangar it was discovered that the gap seal had come out of its position between the elevator and horizontal stabiliser and was damaged considerably. The gap seal then hindered elevator operation in nose down control. This is the first occurrence of this failure in the 20 years of operating the Grobs Type and are an on condition maintenance item. Recommended to limit 3000 hour life limit to the gap seals to ensure good reliability. P/No: 1460856512.
SDR 510022888 | Beech 200BEECH Crew oxygen system—hose fitting ruptured. Oxygen turned on and leak heard from behind pilot oxygen trim jack. Investigation found that hose had ruptured at swaged end of hose. P/No: 17342708. TSN: 7788 hours/7720 cycles.
SDR 510022883 | Airbus A319-115 APU system—APU damaged. While APU in operation on the ground, inlet guide vane delaminated and passed through APU. Three of the compressor blades were damaged. APU replacement is in progress. P/No: 4500001B. TSN: 6850 hours/6626 cycles/176 months.
SDR 510022876 | Cessna T303 Main landing gear—torque link cracked. During periodic inspection, crack found in upper cast mark in LH MLG lower link assembly. P/No: 25410411.
SDR 510022875 | AESL Airtourer T-6 Flight compartment windows—canopy disengaged. While conducting aerobatics, pulled 4.8 G into a looping manoeuvre when the left hand side of the canopy transparency departed the aircraft. Recovered upright then landed. It is though that initially attaching rivets failed with lift loads, giving way to canopy peeling off thereafter.
SDR 510022873 | GULFSTREAM AEROSPACE 500S Wing spar—spar cap cracked and corroded. L/H aileron was removed for access to leading edge skin for repair of corrosion. During the disassembly process, spar was inspected and found cracked (one inch typical length running longitudinally) in the area of the middle hinge mounting. Other ailerons were also found with similar cracks. Repairs in progress. P/No: 25000166.
SDR 510022860 | Air Cruisers Div Of Garrett Corp 64356101 packing damaged. Life raft was removed after being noticed having a low inflation cylinder pressure. Root cause identified as failure of O-ring between pressure indicator and valve assembly. New O-ring was installed taking it from different batch and stock. Consultations underway with the OEM. P/No: B14056907.
SDR 510022859 | Lycoming O540E4B5 Reciprocating engine power section—carburettor contaminated. During first annual maintenance check, carburettor bowl was drained and fuel finger filter checked. Significant fuel contamination was found in both places. Consequently, carburettor was removed and sent for repairs. Fuel system flushing followed.
SDR 510022820 | Rotax ROTAX912 Engine reciprocating—reduction gearbox unserviceable. A large chip of metal was located on reduction gearbox magnetic plug during scheduled maintenance. Gear box removed and broken spline was located on the propeller shaft. One similar defect reported. P/No: 887708. TSN: 1014 hours.
SDR 510022815 | Lycoming IO540F1B5 Engine reciprocating—piston engine worn and damaged. Major engine damage reported due to a badly worn piston pin plug in the No. 2 cylinder. Engine recently inspected against 100 hour and oil filter contamination. Oil filter contamination was excessive. Other 11 piston pin plugs were all either moderately worn or severely worn (up to 0.040 wear on some). This engine was previously overhauled with new cylinder kits which come with new pistons, piston pins and piston pin plugs. This problem seems to be only occurring on R22/R44 engines—not on fixed wing with the same parts fitted. P/No: 0540F1B5. TSN: 5508 hours TSO: 1390 hours.
SDR 510022815 | Lycoming IO540F1B5 Engine reciprocating—piston engine worn and damaged. Major engine damage reported due to a badly worn piston pin plug in the No. 2 cylinder. Engine recently inspected against 100 hour and oil filter contamination. Oil filter contamination was excessive. Other 11 piston pin plugs were all either moderately worn or severely worn (up to 0.040 wear on some). This engine was previously overhauled with new cylinder kits which come with new pistons, piston pins and piston pin plugs. This problem seems to be only occurring on R22/R44 engines—not on fixed wing with the same parts fitted. P/No: 0540F1B5. TSN: 5508 hours TSO: 1390 hours.
SDR 510022815 | Lycoming IO540F1B5 Engine reciprocating—piston engine worn and damaged. Major engine damage reported due to a badly worn piston pin plug in the No. 2 cylinder. Engine recently inspected against 100 hour and oil filter contamination. Oil filter contamination was excessive. Other 11 piston pin plugs were all either moderately worn or severely worn (up to 0.040 wear on some). This engine was previously overhauled with new cylinder kits which come with new pistons, piston pins and piston pin plugs. This problem seems to be only occurring on R22/R44 engines—not on fixed wing with the same parts fitted. P/No: 0540F1B5. TSN: 5508 hours TSO: 1390 hours.
SDR 510022813 | Robinson R44 Tail rotor blades—tail rotor blade cracked. During a pre-flight daily inspection a crack was noticed on one of the tail rotor blades (at the root of the blade). P/No: CO292. TSN: 1250 hours.
SDR 510022804 | Jabiru JABIRU3300 Reciprocating engine power section—cylinder head damaged. Pilot applied full power for a climb to 4000ft for stall testing. Extensive vibration was experienced from the engine bay, power was reduced and an incident free landing was carried out. Cowls were removed and revealed a hole was in the bottom of cylinder head No 6. The head was removed revealing a 40mm hole between the barrel and the cylinder head.
SDR 510022793 | Piper PA22108 Engine cowling system—cowling cracked. Extensive cracking on lower engine cowl surrounding air duct. Cracks stop drilled. Cracking continuing through repair patches and stop drills. Cowl old and fatigued. Cowl skin renewed. P/No: 1425605.
SDR 510022791 | Cessna 208B Elevator tab control system—actuator SUP. The component has been fitted with grease nipples. No evidence of an order or bulletin for this approving this modification can be found. An internal investigation has commenced in order to try and ascertain when this has occurred. Initial observations are that the component has been fitted since manufacture of the aircraft and it has been modified whilst under control of a previous operator. P/No: 26612151.
SDR 510022783 | Boeing 747-438 Hydraulic power system—hydraulic line failed. During approach, following gear down selection, HYD QTY LOW 4 and HYD PRESS SYS 4 EICAS msgs flagged, with complete loss of No. 4 hydraulic system. The NNC was completed and the landing was uneventful. Preliminary engineering investigation found that a temporary repair fitted to a No. 4 system hydraulic line in the aft cargo area had failed. The temporary repair had been fitted during the preceding transit to address a minor hydraulic leak.
SDR 510022769 | Allison 250C20 Engine fuel and control-governor failed. During take-off, the pilot noted a torque split of around 20%. Attempts to adjust the split were attempted but the split stayed the same and the NR was beginning to drop. Engineering inspected and found no issues with rigging, and a ground run had the same No. 2 N2 overspeed again. Subsequent change of the power turbine governor revealed a failure of the drive bearing. P/No: 23065123. TSO: 603 hours/9 months.
SDR 510022718 | Tecnam P2006 Main landing gear attach section—hinge incorrect rigged. After reports of in transit light illuminated after gear retraction troubleshooting was carried out. A screw was discovered on the RH nose gear door which interfered with the operation of the nose wheel fork. There is no rigging procedure for the undercarriage and gear door systems in the maintenance manual. P/No: 26217161.
SDR 510022710 | Canadair CL6002B16p passenger/crew doors—linkage incorrect assembly. Crew noticed cabin door support foot which usually retracts was extended. Z link incorrectly installed (backwards). Disassembled during SB. Full investigation to follow.
SDR 510022704 | Eurocopter AS350B3 Hydraulic power system—filter incorrect dimensions. On a turnaround check it was noticed that one of the hydraulic system impending bypass indicators had ‘popped’. During the course of changing the filter, we were unable to gain the correct clearance through the peel shim pack, on further investigation it was found that the new filter was approximately .45mm shorter than the one being removed. We then measured all our stock of filters and found that they all varied in length and were below the measurement of the original. Airbus Helicopters have acknowledged that there is an issue with the supplied filters, and have issued a Technical Agreement to clean the existing filter. They also asked us to quarantine our stock of effected filters. P/No: 806966.
SDR 510022696 | Airbus A380-842 Landing gear door retract section—hose damaged. One hour into cruise, Y hydraulic system lost fluid. On arrival, hose for L/H BLG centre door was found to have failed. Defective hose replaced, aircraft cleaned and returned to service. These hoses are due for replacement in accordance with SB A380-29-8031. P/No: ABS1401M00AF544.
SDR 510022686 | Cessna 182L Wing spar—spar cracked. Crack found visually during routine CASA Schedule five periodic inspection and AD/CESSNA 180/15 Amdt 4. Crack is in a known area indicated by an AD. Repaired in accordance with Engineering Order. P/No: 0523400111. TSN: 8447 hours TSO: 8447 hours
SDR 510022648 | Hartzell HCD4N3A Propeller system—bearing failed. Half inch diameter ball from bearing discovered failed during propeller overhaul. There were no indications or warnings except potentially metal particles in the expelled grease during propeller servicing at aircraft phase checks, although it is unknown how long the bearing has been in this condition. Probable cause is manufacturing flaw. Damage to adjacent parts will be inspected and replace as necessary, all ball bearings are replaced at overhaul as part of the mandatory replacement parts contained in the overhaul kit. P/No: B6144. TSN: 2726 hours/72 months TSO: 2726 hours/72 months.
SDR 510022622 | Cessna 150L Engine mount section—doubler corroded. During a periodic inspection it was noticed that there was eight x missing rivets and extensive corrosion around the firewall doubler top left side. Engine mount and doubler was removed, the area had not been primed between the Alclad doubler and the steel firewall and severe corrosion had taken place to the doubler and rivets. A serviceable doubler was etch primed and refitted. This area would be prone to corrosion with dissimilar metals and probably required more detailed attention possibly at Engine change or when carrying out the engine frame inspection SID. P/No: 04531165. TSN: 8549 hours/480 months.