Service difficulty report · Air Duct · Doug DC915F

Difficulty date
October 1, 2012
Submitted
October 4, 2012
Operation
Air carrier
Aircraft
N196US
Make and model
Doug DC915F
Aircraft serial
47155
Aircraft time
77,011 hours, 87,743 cycles
Engine
Pwa JT8D7B
Part
Air Duct
Part number
5910090653
Condition
Cracked
Location
Zone 200
Stage of operation
CL
How discovered
O
Nature of condition
E
Precautionary procedure
A

As reported to the FAA. Reports are unverified, and codes are left as the FAA publishes them.

What was found

CREW REPORTED AFTER TAKEOFF UPON CLEANUP AND ACCELERATING IN CLIMB THEY NOTED A VIBRATION CHANGED THROTTLE SETTINGS/NO CHANGE. NO CONTROL ISSUES. CREW DECLARED AN EMERGENCY WITH APPROACH TO RETURN TO DEPARTURE. ACFT RETURNED TO POINT OF DEPARTURE AND LANDED WITHOUT INCIDENT. MX FOUND THE RAM AIR COOLING DUCT FOR LT & RT HEAT EXCHANGERS WITH LOOSE CLAMPS (SLIPPED OFF) ON RUBBER COUPLINGS. LT HEAT EXCHANGER DUCT CRACKED AT RAM AIR INLET FLEX COUPLING MOUNTS. THE LT HEAT EXCHANGER DUCT CRACK WAS WELDED IAW PROCESS STANDARDS 10.225. THE LT & RT HEAT EXCHANGER CLAMPS WERE REINSTALLED AND TIGHTENED. OPS CHECK WAS GOOD. ALL WORK PERFORMED IAW MM 21-20-06. AS A PRECAUTION A VIBE SCAN SURVEY WAS PERFORMED ON BOTH ENGINES IAW MM 72-00-00. NO DEFECTS WERE NOTED AND BOTH ENGINES WITHIN LIMITS. THE ACFT WAS SUBSEQUENTLY TEST FLOWN TO VERIFY THAT VIBRATION WAS NO LONGER PRESENT. TEST FLIGHT WAS SATISFACTORY. ACFT WAS RETURNED TO SERVICE.

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