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May 2013


Aeronca 7AC - Continental A65 - over Essex - 19 May 2013 (201305700) 

Pilot observed an irregular shaped object depart upwards and to the left over the cockpit followed by strong vibration. Throttled back to idle and saw that propeller disc was not as it should be.  Due to vibration he switched off magnetos to stop the engine.  Landed safely in a field without damage.  

Cessna 152  - Lycoming O-235 - Blackpool - 13 March 2013  (201302674)

Smoke in cockpit.  Full emergency declared.  A/c landed safely.  Pilot had reported the smoke had stopped just before landing. 

Cessna 421 - Continental O-520 - Cranfield - 4 March 2013  (201302237) 

During scheduled maintenance, on removal of the outboard de-icing boots on both wings, the mainplane leading edges were found to be excessively corroded.  Thorough inspections recommended at next  maintenance input.  (Note: The mainplane leading edge forms the forward face of the wing fuel tank).  (GASCo Comment: as we do not have the registration we cannot give the age or Serial Number).   

DHC6 Twin Otter - P & W PT6 - Campbeltown  - 3 May 2013 (201304904) 

External fuel leak; on arrival fluctuating readings from aft fuel gauge.  Manual dip carried out and forward tank dipped at 400 lbs and aft tank dipped at just over 200 lbs. Unable to identify if there was a leak due to having flown through rain showers although there was a strong smell of fuel along the belly panels. Tech Log entry from previous flight had indicated a strong fuel smell identified by a passenger but engineering could not find a fault so a/c was returned to service.  Fuel leaks have been logged from the aft tank over the past few days.  When a/c was moved for overnight parking the aft gauge now indicated 75 lbs of fuel. Tech Log entry made and a/c under investigation. 

Diamond DA42 - Austro AE300 - Gamston - 8 March 2013 (201302412)  

Insufficient control clearance was found between a bolt in the rudder system and the nose wheel steering mechanism during a post inspection rebuild.  A minimum clearance of 2 mm is required but the clearance found was 0.8 mm. Inspection showed an incorrect part number for the bolt fitted.  The system has not been disturbed since manufacture so it is believed that this has been the situation since build. (The minimum clearance is specified by MSB 42NG-016/1 which is N/A to this airframe by serial number). When the correct size bolt was fitted however, sufficient clearance was obtained. Manufacturer advised.  

Grob G115 - Lycoming O-360 - Cranwell  - 23 April 2013 (201305032)  

A progressive level of RPM decay was experienced during a practice display sequence and was unacceptable towards the end of the flight.  During the penultimate stall turn, an RPM decay to 1700 was experienced with associated oil pressure drop to 30 psi.  Tech Log entry made.  Engineers report states that following installation of the MT propeller on this a/c type, several confirmed reports of RPM decay have been reported during certain aerobatic manoeuvres especially in vertical or near zero G conditions. The inverted oil system is suspected as being a contributory factor and the manufacturers and maintenance organisations are in consultation.  All company owned a/c have been temporarily removed from operation until advice from the OEM has been provided.  

Piper PA28 - Thielert Centurion 1.7 - Wolverhampton - 27 May 2013 (20130 5978)  

Undercarriage oleo assembly found to be loose.   During replacement of the LH main wheel following a tyre change (due to  a flat tyre in the field) it was noticed that the undercarriage oleo assembly was moving.  Further inspection revealed the four top spar screws and three of the lower spar bolts to be loose. The fourth lower bolt had sheared off and was seen to be heavily rusted.   Significant slop in the leg suggests fretting damage to the spar caps and elongation of the bolt holes. Cracks were visible on the upper leg casing.   Reporter is not the a/c  maintainer and has informed the operator.  

Robin DR400 - Lycoming O-235 - Headcorn  - 11 March 2013  (201302647)  

Returned after a short flight due to burning electrical smell.  Found alternator bolts missing and belt on pulley had come away.  Alternator had been replaced 77hrs prior to flight but records did not show split pin installation.  Task Cards updated to check security of split pins at 50hr checks.  

Vans RV4 - Lycoming O-320 - Stansted - 3 May 2013 (201304858)  

While in the cruise, the transponder indicated the a/c was at 2,800 ft instead of actual 1,100 ft resulting in Terminal Control believing it had infringed LTMA (Class A).  Traffic info and avoiding action given by T.C. to a Stansted inbound A320; a Stansted inbound B737 was also delayed. 


Aerospatiale AS355 - Allison 250  - Gloucestershire - 18 March 2013  (201302805)  

Smoke and electrical burning smell in the cockpit. Engines shut down and emergency declared.  Slight electrical burning smell was noticed on completion of initial start up sequence during pre take-off checks. Smoke was then observed coming from the upper console on P1 side.  Fire services assistance requested and emergency cut-off switch selected.  

Aerospatiale SA365  - Turbomeca Arriel - Kyle of Lochalsh - 26 March 2013 (201303418)  

Just after take off passing 500ft in the initial climb, 'AUX hyd' caption illuminated just after undercarriage had completed travelling up. 'Aux hyd' switched to bypass and caption extinguished. Gear selected down normally and a/c returned. Fault traced to a micro switch on the landing gear nose leg.  

Agusta A109 - P & W P200 - Redhill -  25 Feb 2013 (201302897)  

A/c returned due to landing gear failure to retract.  Several attempts were made to retract the landing gear but no success, landed safely.  Engineers inspection found that the safety locking pin was not disengaging, preventing the lever from moving.  The locking pin's disengagement is activated by the weight-on-wheels switch, which was found to be just on the cusp of activating.  The switch rigging was adjusted to operate correctly, tested, all satisfactory and a/c returned to service.  

Bolkow 105 - Allison 250 - Bristol Filton - 26 March 2013  (20130 3196)  

The helicopter returned due to generator failure in the cruise.   ECL actioned for under voltage and an uneventful landing. Engineering investigation traced the fault to a sheared starter-generator spline drive.  Starter generator-replaced and tested,
helicopter returned to service.  

Bolkow 105 - Allison 250 - Bristol Filton - 27 March 2013  (201303268)  

No. 1 engine compressor found damaged during inspection after the engineer noticed a small 8 mm bolt lying on the LH transmission decking.  The bolt was identified as having come from the No. 1 engine intake ring.   Inspection of the engine intake revealed impact damage to the 1st stage compressor blades of the No. 1 engine, helicopter removed from service.  In depth inspection found that all 16 blades on the 1st stage had been damaged but no damage to other stages, or to the compressor casings or stator blades.  The damage was within the blendable area and limits of the OEM so were blended and polished iaw OEM 72-30-00.  Checked, tested and released to service.  

Eurocopter EC135 - P & W -  Cranfield - 9 May 2013  (201305179)    

During cruise flight crew and passengers became aware of acrid electrical fumes. Non essential electrics isolated and a/c diverted.  Fault traced due to vibration to a chaffed and burnt through electrical cable supplying instrument lighting.  

MD 902  -  P & W PW200  - Nr Harpenden -  3 April 2013 (201303439)  

PAN declared and emergency landing made due to burning smell in cockpit.  A/c landed safely on a golf course and engineering assistance sought.  It was suspected that the electronic attitude and direction indicator (EADI) was the source so the unit was isolated by pulling the C/B and a ground run confirmed no further smell of burning.  The a/c returned to base where the EADI unit and its generator were replaced.  

MD900 - P & W PW200 - Worksop  - 2 March 2013 (201302943)  

Returned due to electronic engine control (EEC) failure.  A/c in orbit at 300ft to check for landing site.   EEC failure warning.  RH engine torque frozen at 47%,  LH engine normal parameters.  EEC reset procedure carried had but had no effect. Returned using manual throttle control for an uneventful arrival.  Oil found on three RH engine plugs.  

MD900  - P & W P200 - Gloucestershire - 1 March 2013  (201303004)  

Main rotor drive ring found cracked during daily inspection.  A/c inspected for installation issue or other factors which could have caused the failure, none found.  Drive ring replaced iaw CSP-900RMM-2.  

MD900 - P & W - Northolt - 4 April 2013 - (201303604)  

After flight, the fuel filler cap was found not correctly secured.  After landing and shutting down, the pilot informed the engineer that there appeared to be an 'o' ring or seal hanging from the fuel filler neck cap lanyard. This was confirmed to be the fuel cap back-up ring.  Subsequent inspections found the fuel filler neck to main fuel tank joint correctly assembled with no signs of damage.  New back-up ring fitted.  Further investigations found that at a different base, the fuel nozzle used by the refuelling contractor had a large diameter flattened end that could catch the back up ring during refuelling. The operator will review refuelling procedures at this base and will issue a Flight Safety Circular to bring to the attention of their crews.  Fleet check initiated.  

MD900 - P & W - Northolt - 8 May 2013  (201305067) 

NOTAR felt/metal seal found to be debonding from its backing plate. Seal had been replaced Jan 2013 during the a/c annual service and the a/c had flown 93 hrs since that time. Further inspection found delamination of felt liner from aluminium backing.  NOTAR fan and associated items and area visually inspected with no signs of damage found.  NOTAR felt seal replaced and a/c returned to service.  Felt seal returned to manufacturer for analysis.



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