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The APU was removed and further investigation revealed a completely detached broken bracket lying in the APU compressor inlet duct. This piece was identified as a broken flange from the inside of the inlet duct. Further inspection of the compressor rotor showed significant damage from contact with the aforementioned broken bracket. The elbow tube assembly that is attached to the inlet plenum , P/N 3846007-1, was also found to be loose and worn from vibration.
When this APU was installed, it was reported to have a high pitch whine but the cause was never determined. However, the operation was normal until it would not accelerate on start-up. A possible cause of the "whine" was from an out-of-balance condition.
Continued operation of the subject APU resulted in APU fatigue-related failures of the compressor inlet bracket, which then contacted the compressor rotor, creating a massive "out-of-balance" condition and eventual failure of the APU plenum assembly and other parts.
BOMBARDIER CL600 2B16 (604) SDR # 20040514001
Low-Limit Valve Detached
After engine start, crew was unable to obtain cold air-conditioned air out of the left air-conditioning pack. Engines were shut down and maintenance was notified of the snag. Maintenance discovered that the low-limit valve butterfly, P/N 979580-4, was no longer attached to its shaft.
The butterfly was located in the duct just below the air-cooling turbine. The air-cooling turbine was also replaced as a precaution due to suspected FOD damage.

 

 

CESSNA 210L SDR # 20040423003
Lubrication Type Unclear
The main landing gear down-lock spring assembly sliding action was restricted by accumulation of dirt and debris. The down-lock, P/N 124160-1, was unable to fully engage, resulting in an "unsafe" gear indication. Inspection revealed wet lubrication attracted debris and dirt in the spring assembly concentric sleeve and spring.
Section 2 of the Cessna inspection manual is vague regarding lubrication type and applicability, and states in part - "…and any other friction point obviously requiring lubrication".
The submitter recommends that dry lubrication be used in this area and increased awareness of individual inspection programs for aircraft operating in "off-airport" locations, such as gravel and dusty strips.
DIAMOND DA20 A1 SDR # 20040203013
Muffler Obstructed
When the muffler tailpipe was found nearly snapped off; a detailed examination revealed that the internal baffles in the muffler were broken off at the weld. The muffler baffles obstructed the exhaust outlet port creating a pressure build-up inside the muffler and caused loss of engine power.
The operator has started a fleet-campaign and now carries out a "tap-test" inspection to determine if the muffler baffles are excessively loose or broken off.
The exhaust system components are subjected to extreme temperatures, and the resulting expansion and contraction produce stresses that often result in cracks and distortion due to warpage. Regular and thorough inspections are especially important to detect internal muffler failures.
　
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