Chantilly Air Inc.

Sanction: $10,000 · case closed 2023-04-26

Part: SPRING — MISSING (BRAKE ASSY)

UPON RECEIVING BRAKE ASSY INTO SHOP FOR INSPECTION AND OVERHAUL, FOUND THAT SPACER TUBES PN 5012942 (4EA) WERE MISSING FROM RETURN SPRING ASSYS. BRAKE HAD BEEN PREVIOUSLY OVERHAULED AT OTHER REPAIR CENTER UNDER NR AEB-11088.

Part: SPACER — MISSING (BRAKE ASSY)

UPON RECEIVING BRAKE ASSY INTO SHOP FOR INSPECTION AND OVERHAUL , FOUND THAT SPACER TUBES PN 5012942. (4 EA) WERE MISSING FROM RETURN SPRING ASSEMBLIES. BRAKE HAD BEEN PREVIOUSLY OVERHAULED AT OTHER REPAIR CENTER UNDER NR AEB-11087.

Part: DISC — WRONG PART (BRAKE ASSY)

UPON CONDUCTING INSPECTION AND OVERHAUL FOUND: SPACER TUBES PN 5012942 WERE MISSING FROM RETURN SPRING ASSEMBLIES. INCORRECT PRESSURE PLATE INSTALLED ON BRAKE ASSY. SHOULD BE PN 5006890, INSTALLED WAS PN 5005117. P/N 5006890 MEASURES .240 INCH THICK, PN 5005117 MEASURES .210 INCH THICK. INCORRECT WEAR PAD WAS INSTALLED ON PRESSURE PLATE. SHOULD HAVE BEEN PN 5007328, INSTALLED WAS 5005119. INCORRECT STATIONARY DISC INSTALLED ON BRAKE ASSY. SHOULD BE PN 5006892, INSTALLED WAS P/N 9544028. PN 5006892 MEASURES .240 INCH THICK, PN 9544028 MEASURES .210 INCH THICK. INCORRECT INSULATORS WERE INSTALLED IN PISTONS, SHOULD HAVE BEEN PN 5006895-1, INSTALLED WERE PN 9535042-1. BRAKE ASSY HAD BEEN PREVIOUSLY OVER

Part: INSULATOR — WRONG PART (BRAKE ASSY)

UPON CONDUCTING INSPECTION AND OVERHAUL FOUND: SPACER TUBES PN 5012942 WERE MISSING FROM RETURN SPRING ASSEMBLIES. INCORRECT PRESSURE PLATE INSTALLED ON BRAKE ASSY. SHOULD BE PN 5006890, INSTALLED WAS PN 5005117. PN 5006890 MEASURES .240 INCH THICK, PN 5005117 MEASURES .210 INCH THICK. INCORRECT WEAR PAD WAS INSTALLED ON PRESSURE PLATE. SHOULD HAVE BEEN PN 5007328, INSTALLED WAS PN 5005119. INCORRECT STATIONARY DISK INSTALLED ON BRAKE ASSY. SHOULD BE PN 5006892, INSTALLED WAS PN 9544028. PN 5006892 MEASURES .240 INCH THICK, PN 9544028 MEASURES .210 INCH THICK. INCORRECT INSULATORS WERE INSTALLED IN PISTONS, SHOULD HAVE BEEN PN 5006895-1, INSTALLED WERE PN 9535042-1. BRAKE ASSY HAD BEEN PREVIOUSLY OVE

Part: SPACER — MISSING (BRAKE ASSY)

OPERATOR SUSPECTED MISSING PARTS FROM BRAKE ASSEMBLIES JUST OUT OF OVERHAUL. UPON CONDUCTING VISUAL INSPECTION, FOUND THAT SWAGE ADJUSTER ASSEMBLIES WERE INCORRECTLY SET FOR THIS SERIES OF BRAKE. THE SWAGES WERE SET AT A DEPTH OF 0.18 INCH BELOW FLUSH OF ADJUSTER TUBE, THEY SHOULD HAVE BEEN SET FLUSH WITH THE TOP OF THE ADJUSTER TUBE. FURTHER INSPECTION FOUND THAT INCORRECT RETURN PINS WERE INSTALLED. SHOULD HAVE BEEN P/N 5001421, INSTALLED WERE P/N 9535044. THE LATER RETURN PIN IS SHORTER AND NOT FOR USE ON THIS BRAKE. SPACER TUBES (P/N 5012942) WERE MISSING FROM THE RETURN SPRING ASSEMBLIES. THE BRAKE ASSY HAD BEEN OVERHAULED AT REPAIR CENTER AND HAD NOT BEEN INSTALLED ON THE AIRCRAFT PRIOR TO THIS EVA

Part: SPACER — MISSING (BRAKE ASSY)

OPERATOR SUSPECTED MISSING PARTS FROM BRAKE ASSEMBLY JUST OUT OF OVERHAUL. UPON CONDUCTING VISUAL INSPECTION, FOUND THAT SWAGE ADJUSTER ASSEMBLIES WERE INCORRECTLY SET FOR THIS SERIES OF BRAKE. THE SWAGES WERE SET AT A DEPTH OF 0.18 INCH BELOW FLUSH OF ADJUSTER TUBE, THEY SHOULD HAVE BEEN SET FLUSH WITH THE TOP OF THE ADJUSTER TUBE. FURTHER INSPECTION FOUND THAT INCORRECT RETURN PINS WERE INSTALLED. SHOULD HAVE BEEN P/N 5001421, INSTALLED WERE P/N 9535044. THE LATER RETURN PIN IS SHORTER AND NOT FOR USE ON THIS AC BRAKE. SPACER TUBES (P/N 5012942) WERE MISSING FROM THE RETURN SPRING ASSEMBLIES. THE BRAKE ASSY HAD BEEN OVERHAULED AT OTHER REPAIR CENTER AND HAD NOT BEEN INSTALLED ON THE AIRCRAFT PRIOR TO T

Part: SPACER — MISSING (BRAKE ASSY)

OPERATOR SUSPECTED MISSING PARTS FROM BRAKE ASSEMBLY JUST OUT OF OVERHAUL. UPON CONDUCTING VISUAL INSPECTION, FOUND THAT SWAGE ADJUSTER ASSEMBLIES WERE INCORRECTLY SET FOR THIS SERIES OF BRAKE. THE SWAGES WERE SET AT A DEPTH OF 0.18 INCH BELOW FLUSH OF ADJUSTER TUBE, THEY SHOULD HAVE BEEN SET FLUSH WITH THE TOP OF THE ADJUSTER TUBE. FURTHER INSPECTION FOUND THAT INCORRECT RETURN PINS WERE INSTALLED. SHOULD HAVE BEEN P/N 5001421, INSTALLED WERE P/N 9535044. THE LATER RETURN PIN IS SHORTER AND NOT FOR USE ON THIS AC BRAKE. SPACER TUBES P/N 5012942 WERE MISSING FROM THE RETURN SPRING ASSEMBLIES. THE BRAKE ASSY HAD BEEN OVERHAULED AT OTHER REPAIR CENTER AND HAD NOT BEEN INSTALLED ON THE AIRCRAFT PRIOR TO THI

Part: SPACER — MISSING (BRAKE ASSY)

OPERATOR SUSPECTED MISSING PARTS FROM BRAKE ASSEMBLY JUST OUT OF OVERHAUL. UPON CONDUCTING VISUAL INSPECTION, FOUND THAT SWAGE ADJUSTER ASSEMBLIES WERE INCORRECTLY SET FOR THIS SERIES OF BRAKE. THE SWAGES WERE SET AT A DEPTH OF 0.18 INCH BELOW FLUSH OF ADJUSTER TUBE, THEY SHOULD HAVE BEEN SET FLUSH WITH THE TOP OF THE ADJUSTER TUBE. FURTHER INSPECTION FOUND THAT INCORRECT RETURN PINS WERE INSTALLED. SHOULD HAVE BEEN P/N 5001421, INSTALLED WERE P/N 9535044. THE LATER RETURN PIN IS SHORTER AND NOT FOR USE ON THIS AC BRAKE. SPACER TUBES P/N 5012942 WERE MISSING FROM THE RETURN SPRING ASSEMBLIES. THE BRAKE ASSY HAD BEEN OVERHAULED AT OTHER REPAIR CENTER AND HAD NOT BEEN INSTALLED ON THE AIRCRAFT PRIOR TO THI

Part: SPRING — MISSING (BRAKE ASSY)

BRAKE ASSEMBLY SENT INTO SHOP FOR MISSING RETURN SPRING ASSY. UPON CONDUCTING REPAIR TO REPLACE THE MISSING RETURN SPRING ASSEMBLY, FOUND THAT THE SPACER TUBES (PN 5012941) WERE MISSING FROM THE REMAINING THREE RETURN SPRING ASSEMBLIES. BRAKE ASSY HAD BEEN PREVIOUSLY OVERHAULED AT OTHER REPAIR CENTER.

Part: SWITCH — SHORTED (INSTRUMENT PANEL)

WHILE RETURNING TO AIRPORT, THE COPILOTS ALTIMETER BREAKER POPPED, WHICH IN TURN DISABLED THE NR2 ALTIMETER/ADDU. THE AC LANDED 10 MINUTES LATER WITHOUT INCIDENT AND THE NR2 ALTIMETER FAILURE WAS REPORTED TO MAINTENANCE. WHEN THIS PROBLEM WAS INVESTIGATED IT WAS FOUND THAT BOTH ALTIMETER BREAKERS WERE POPPED AND BOTH ALTIMETER/ADDU WERE INOPERATIVE. THE PROBLEM WAS EVENTUALLY TRACED TO A SHORTED AIR DATA SWITCH PANEL WHICH WAS INSTALLED IN THE INSTRUMENT PANEL AS NEW DURING THE STC MODIFICATION. FAILURE OF THIS COMPONENT CAUSED BOTH ALTIMETERS, BOTH ADDUS, ALL MODE C TRANSPONDER INFO, AND THE AUTOPILOT TO BECOME INOPERATIVE.