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September 2015


Beech 200: P & W PT6:  - 10/07/2015 (201510770)

Operator reported propeller grease/oil leakage.  Propeller was removed and sent for investigation, following disassembly it was noted that the piston nut was loose allowing the piston to pitch and oil to propagate to both sides of the piston. (The nut should be torqued to 100 ft lb.).  The non-pressure side of the piston does not have any seal other than a phenolic bush between the rod and pitch adjustment sleeve hence if the mating surfaces do form a seal the propeller will either eventually hydraulic lock or the phenolic bush does not seal and will lead to loss of engine oil. The propeller was reassembled with new seals, balanced and operationally tested before being returned for installation. The operator requested that an MOR be submitted.  Investigation under 01512502: see below. 

Beech 200: P & W PT6:  -  08/09/2015 (201512502)

Both propellers were received by the reporter for Overhaul as time expired on calendar life limit.  During inspection the following defects were noted on both propellers: 1. Preload plate SB not complied with in any form, either by replacement of plates or the new painting procedure. (This was mandatory at last overhaul). 2. Pitch change rods have had new holes drilled for the top plug bolt. (This is an unapproved modification and should never have been carried out). On consultation the OEM requested immediate retirement of both rods. 3. Pitch change rod had been damaged during previous installation; this had resulted in an incorrectly torqued piston and resulting piston damage.  A very similar defect to item 3 was raised under MOR, this resulted in an in-flight oil leak.  With the nature of damage to the rod (similar damage to opposing propeller, but not quite as severe) and the previous incorrect fitment raised in the earlier MOR this shows a clear lack of correct/specialised tooling required for the piston installation.  It should also be noted that reference item 1, the pre-load plate SB has been found unincorporated on 2-3 previous pairs of propellers overhauled by the same facility.   

Grob G115: Lycoming O-360: Cranwell - 17/09/2015 (201513880)

Whilst conducting the walk around it was noted that the canopy security lock was loose, allowing it to drop into the locked position.  With the lock in this position the canopy cannot be fully closed. Engineering assistance was sought, but there was no key available for the lock.  Had this happened during flight, there would be no method of opening the locked canopy either post flight, furthermore during an emergency the canopy could not be jettisoned.  

Grob G115: Lycoming O-360: Wittering - 15/09/2015 (201513871)

A 2 cm crack was found on the elevator upper surface. The crack was from a corner of the inboard hinge cut- out on the left elevator portion. The crack was observed post flight during the 'four points' check. On closer inspection the crack was through the fibres and not just a cosmetic surface defect. The sortie completed, straight and level 2, the aircraft was placed U/S.  

Piper PA28: Lycoming O-320: Popham - 16/08/2015 (201511997)

While climbing out, as the pilot was levelling out and as he reduced power there was a load bang and a rush of air.  He found the rear seat passenger was pointing at the left rear window which was missing. It did not effect the handling of the aircraft but there was a risk of personal injury from the shrapnel.  One piece flew forward and bounced off the instrument panel.  It was fortunate the rear seat passenger was sitting on the right where she was unharmed.  The pilot reduced speed and after confirming there was no effect on the aircraft handling and the passengers were unharmed he continued and made an uneventful landing.  The window was the last remaining original piece of Perspex on the 1967 aircraft.  (GASCo Comment: it might be as well for all owners of aircraft with Perspex of this age subject to years of UV degradation to consider replacement at a convenient opportunity rather than have it shatter in a more hazardous situation or in an inconvenient and possibly expensive situation).  



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