Sunday, November 3, 2019

Flight Control System Malfunction/Failure: Cessna 560 Encore, N774SB; incident occurred February 09, 2016 at Dallas Love Field Airport (KDAL), Texas

The National Transportation Safety Board did not travel to the scene of this incident.

Additional Participating Entities:
Federal Aviation Administration / Flight Standards District Office; Irving, Texas
SevenBar Aviation; Dallas, Texas

Aviation Incident Factual Report - National Transportation Safety Board: https://app.ntsb.gov/pdf

Investigation Docket - National Transportation Safety Board: https://dms.ntsb.gov/pubdms

http://registry.faa.gov/N774SB

Location: Dallas, TX
Incident Number: CEN16IA103
Date & Time: 02/09/2016, 0800 CST
Registration:N774SB 
Aircraft: Cessna 560
Aircraft Damage:None 
Defining Event: Flight control sys malf/fail
Injuries: 5 None
Flight Conducted Under: Part 135: Air Taxi & Commuter - Non-scheduled - Air Medical (Unspecified)

On February 9, 2016, about 0800 central standard time, a Cessna 560 Encore airplane, N774SB, experienced a flight control malfunction during the takeoff from Dallas Love Field Airport (DAL), Dallas, Texas. The two flight crewmembers and three passengers on-board were not injured. The airplane did not sustain damage. The airplane was registered to Bridgeway Enterprises, Inc. and operated by SevenBar Aviation under the provisions of Title 14 Code of Federal Regulations Part 135 as an on-demand air taxi. Visual meteorological conditions prevailed for the flight, which operated on an instrument flight rules flight plan. The flight was destined for McCurtain County Regional Airport (4O4), Idabel, Oklahoma.

The copilot stated that during takeoff rotation he had difficulty maintaining runway heading and the airplane experienced a tendency to roll to the right. As speed was increased, the pressure required on the control yoke to maintain level attitude increased. The copilot transferred control of the airplane to the Captain who experienced the same flight control difficulty. The Captain attempted to adjust the aileron trim; however, the trim control knob would not move, and the trim indicator appeared centered. The flight crew contacted air traffic control, requested to return to DAL, and declared an emergency. When the airspeed was decreased during the approach, the right roll control pressure decreased, and the flight crew was able to free the aileron trim control. The flight crew landed the airplane at DAL without further incident.

The day before the flight, on February 8, 2016, maintenance personnel had completed an inspection of the cockpit pedestal; which required removal of the control heads for the autopilot, the flight management systems, the multi-functional displays, etc. from the pedestal. The pedestal was cleaned and reassembled.

After the crew returned from the incident flight stating the aileron trim tab control knob was "jammed" and "wanted to roll right," the mechanic opened the pedestal area and observed the cannon plug on the back of the autopilot control head was contacting the aileron trim gear mechanism. Additionally, the wires extending from the cannon plug exhibited chaffing. Maintenance personnel then inspected the aileron trim system for any other possible anomalies, finding the trim indicator position in the cockpit indicted a neutral position when the trim was elevated above the trailing edge of the aileron. Maintenance personnel adjusted the trim tab and verified its' correct indication in the cockpit.

A review of the Cessna Model 560 Maintenance Manual revealed there was no step in the maintenance procedure for "Control Pedestal Area General Inspection" to ensure there was enough separation between the autopilot control head/wiring harness and the aileron trim tab control gearing to prevent interference. Following the incident, in August 2016, Textron Aviation implemented a change to the C560 and C550 airplane's maintenance manuals to include a step to wrap the wiring harness in a protective sleeve and verify separation between the autopilot control head/wiring harness and the aileron trim tab control. Textron Aviation also issued a mandatory Service Letter for the C560 and C550 that provided instructions to inspect for damage and correct wire harness positioning. 

Pilot Information

Certificate: Airline Transport; Flight Instructor
Age: 63, Male
Airplane Rating(s): Multi-engine Land; Single-engine Land; Single-engine Sea
Seat Occupied: Right
Other Aircraft Rating(s): None
Restraint Used:
Instrument Rating(s): Airplane
Second Pilot Present: Yes
Instructor Rating(s): Airplane Multi-engine; Airplane Single-engine; Instrument Airplane
Toxicology Performed: No
Medical Certification: Class 1 Without Waivers/Limitations
Last FAA Medical Exam: 10/26/2015
Occupational Pilot: Yes
Last Flight Review or Equivalent: 10/08/2015
Flight Time: 9025 hours (Total, all aircraft), 300 hours (Total, this make and model), 8219 hours (Pilot In Command, all aircraft), 53 hours (Last 90 days, all aircraft), 13 hours (Last 30 days, all aircraft)

Co-Pilot Information

Certificate: Airline Transport; Flight Instructor
Age: 49, Male
Airplane Rating(s): Multi-engine Land; Single-engine Land
Seat Occupied: Left
Other Aircraft Rating(s): None
Restraint Used:
Instrument Rating(s): Airplane
Second Pilot Present: Yes
Instructor Rating(s): Airplane Single-engine
Toxicology Performed: No
Medical Certification: Class 1 With Waivers/Limitations
Last FAA Medical Exam: 08/26/2015
Occupational Pilot: Yes
Last Flight Review or Equivalent: 01/29/2016
Flight Time: 4031 hours (Total, all aircraft), 23 hours (Total, this make and model), 3880 hours (Pilot In Command, all aircraft), 56 hours (Last 90 days, all aircraft), 13 hours (Last 30 days, all aircraft)

Aircraft and Owner/Operator Information

Aircraft Make: Cessna
Registration: N774SB
Model/Series: 560 Undesignated
Aircraft Category: Airplane
Year of Manufacture: 2005
Amateur Built: No
Airworthiness Certificate:Normal 
Serial Number: 560-0684
Landing Gear Type: Retractable -
Seats: 7
Date/Type of Last Inspection: 02/08/2016, Continuous Airworthiness
Certified Max Gross Wt.: 16630 lbs
Time Since Last Inspection:
Engines: 2 Turbo Fan
Airframe Total Time: 2512.3 Hours at time of accident
Engine Manufacturer: Pratt & Whitney Canada
ELT: C126 installed, not activated
Engine Model/Series: PW535A
Registered Owner: Bridgeway Enterprises Inc
Rated Power: 3400 lbs
Operator: SEVEN BAR FLYING SERVICE INC
Operating Certificate(s) Held: On-demand Air Taxi (135)
Operator Does Business As:
Operator Designator Code: GNLA 

Meteorological Information and Flight Plan

Conditions at Accident Site: Visual Conditions
Condition of Light: Day
Observation Facility, Elevation: KDAL, 487 ft msl
Distance from Accident Site:
Observation Time: 1353 UTC
Direction from Accident Site:
Lowest Cloud Condition: Few / 30000 ft agl
Visibility:  10 Miles
Lowest Ceiling:
Visibility (RVR):
Wind Speed/Gusts: Calm /
Turbulence Type Forecast/Actual: / None
Wind Direction:
Turbulence Severity Forecast/Actual:
Altimeter Setting: 30.3 inches Hg
Temperature/Dew Point: 3°C / -11°C
Precipitation and Obscuration: No Obscuration; No Precipitation
Departure Point: Dallas, TX (DAL)
Type of Flight Plan Filed: IFR
Destination: Idabel, OK (4O4)
Type of Clearance: IFR
Departure Time: 0800 CST
Type of Airspace:Class B  

Airport Information

Airport: DALLAS LOVE FIELD (DAL)
Runway Surface Type: Concrete
Airport Elevation: 486 ft
Runway Surface Condition: Dry
Runway Used: 31R
IFR Approach: Visual
Runway Length/Width: 7752 ft / 150 ft
VFR Approach/Landing: None

Wreckage and Impact Information

Crew Injuries: 2 None
Aircraft Damage: None
Passenger Injuries: 3 None
Aircraft Fire: None
Ground Injuries: N/A
Aircraft Explosion: None
Total Injuries: 5 None
Latitude, Longitude: 32.847222, -96.851667 (est)

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