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20080913851799I

Incident · No damage
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FAA incident report · Diamon DA 40 · San Carlos, CA · September 13, 2008

FAA Aviation Safety Information Portal

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Date
September 13, 2008 · 10:00 local
Place
San Carlos, CA
Airport
San Carlos
Phase of flight
Climb
Operating rules
General operating rules (Part 91)
Damage
No damage
Aircraft
N419JS
NTSB investigation
NTSBSEA08IA217
Reported as
Diamon DA40
Reported engine
Lycoming IO360M1A
People aboard
1
Fatal injuries
0
Pilot’s flight hours
732 total599 in this make and model65 in the last 90 days
N419JSRegistered now · Diamond Aircraft Ind DA 40S/N 40.439 · Built 2004Airframe modelDiamond Aircraft Ind DA 40Engine modelLycoming IO-360-M1A+Reciprocating

From the FAA’s Accident/Incident Data System (AIDS), through its Aviation Safety Information Portal, as reported. The NTSB investigates accidents separately, and its record of an accident is the fuller one. The aircraft is matched to the registry by N-number and event date, checked against the reported make and model; the registry’s history has gaps, so older matches can be wrong. Compare the reported make and model.

What happened

The FAA’s narrative, in sentence case. The FAA writes it in capitals and removes private details.

(-23) On climb, engine speed exceeded the 2700 red line RPM limit to 2800. Overspeed warning was indicated on the G1000. RPM reduction using the propeller governor control was unsuccessful. The pilot subsequently used throttle control to reduce the engine RPM, declared an emergency and landed safely. The pilot reports feeling and hearing a thump from the engine during landing. A repair station duplicated the problem on an engine ground run. A visual inspection revealed a small extrusion near the top of the crankcase, above nr 2 cylinder. Inspection of the oil filter and suction screen showed substantial metal contamination and small ball bearings. The propeller governor was removed. The pilot valve assy fell out of the governor. The engine was torn down and the inspection revealed destruction of both intake and exhaust lifter bodies of nr 1 cylinder and extensive internal damage to the engine. A small ball bearing was found embedded in the crankcase under one of the damaged lifter bodies. The propeller governor has been sent to the NTSB for further examination.

As the FAA filed it

(-23) ON CLIMB, ENGINE SPEED EXCEEDED THE 2700 RED LINE RPM LIMIT TO 2800. OVERSPEED WARNING WAS INDICATED ON THE G1000. RPM REDUCTION USING THE PROPELLER GOVERNOR CONTROL WAS UNSUCCESSFUL. THE PILOT SUBSEQUENTLY USED THROTTLE CONTROL TO REDUCE THE ENGINE RPM, DECLARED AN EMERGENCY AND LANDED SAFELY. THE PILOT REPORTS FEELING AND HEARING A THUMP FROM THE ENGINE DURING LANDING. A REPAIR STATION DUPLICATED THE PROBLEM ON AN ENGINE GROUND RUN. A VISUAL INSPECTION REVEALED A SMALL EXTRUSION NEAR THE TOP OF THE CRANKCASE, ABOVE NR 2 CYLINDER. INSPECTION OF THE OIL FILTER AND SUCTION SCREEN SHOWED SUBSTANTIAL METAL CONTAMINATION AND SMALL BALL BEARINGS. THE PROPELLER GOVERNOR WAS REMOVED. THE PILOT VALVE ASSY FELL OUT OF THE GOVERNOR. THE ENGINE WAS TORN DOWN AND THE INSPECTION REVEALED DESTRUCTION OF BOTH INTAKE AND EXHAUST LIFTER BODIES OF NR 1 CYLINDER AND EXTENSIVE INTERNAL DAMAGE TO THE ENGINE. A SMALL BALL BEARING WAS FOUND EMBEDDED IN THE CRANKCASE UNDER ONE OF THE DAMAGED LIFTER BODIES. THE PROPELLER GOVERNOR HAS BEEN SENT TO THE NTSB FOR FURTHER EXAMINATION.

NTSB investigation

The NTSB’s investigation of this event, with its probable cause and findings. Matched to this report by N-number and date.

NTSB SEA08IA217Incident · No injuriesIncident investigationFinal reportSan Carlos, CAThe improper assembly of the governor during manufacture.Sep 13, 2008 · Minor damage