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An MD11 with recurring #1 engine idg malfunctions after a #1 engine change was discovered to have 2 engine connectors swapped.
| Attributes | |
| ACN | 519565 |
| Time | |
| Date | 200107 |
| Day | Sun |
| Local Time Of Day | 1201 To 1800 |
| Place | |
| Locale Reference | airport : zzz.airport |
| State Reference | US |
| Altitude | agl single value : 0 |
| Environment | |
| Light | Daylight |
| Aircraft 1 | |
| Operator | common carrier : air carrier |
| Make Model Name | MD-11 |
| Operating Under FAR Part | Part 121 |
| Flight Phase | ground : maintenance |
| Person 1 | |
| Affiliation | company : air carrier |
| Function | maintenance : lead technician |
| Qualification | technician : powerplant technician : fcc technician : airframe |
| Experience | maintenance lead technician : 16 |
| ASRS Report | 519565 |
| Person 2 | |
| Affiliation | company : air carrier |
| Function | maintenance : technician |
| Qualification | technician : fcc technician : repairman |
| Experience | maintenance avionics : 13 maintenance technician : 8 |
| ASRS Report | 519564 |
| Events | |
| Anomaly | aircraft equipment problem : critical maintenance problem : improper documentation maintenance problem : improper maintenance non adherence : far non adherence : published procedure |
| Independent Detector | aircraft equipment other aircraft equipment : #1 eng idg indications |
| Resolutory Action | none taken : detected after the fact |
| Consequence | other |
| Factors | |
| Maintenance | contributing factor : schedule pressure performance deficiency : repair performance deficiency : testing performance deficiency : fault isolation performance deficiency : inspection |
| Supplementary | |
| Problem Areas | Aircraft Maintenance Human Performance |
| Primary Problem | Maintenance Human Performance |
Narrative:
My crew was tasked to change the #1 engine on an MD11. The engine connectors were secured and the engine passed inspection and post change engine run. The next day, #1 engine electrical power from the idg malfunctioned. The idg was replaced and checked per maintenance manual. 2 days later, maintenance at xyz found engine connectors swapped. If these connectors were swapped initially, then the previous checks would not have worked. The connectors were removed and reinstalled for troubleshooting previously. I do not believe that my crew crossed the connectors. After each engine change, there are specific checks done by lead amt's and with inspectors present. These checks were done twice by different individuals. I believe the connectors were removed for troubleshooting after the engine change and then reinstalled incorrectly.
Original NASA ASRS Text
Title: AN MD11 WITH RECURRING #1 ENG IDG MALFUNCTIONS AFTER A #1 ENG CHANGE WAS DISCOVERED TO HAVE 2 ENG CONNECTORS SWAPPED.
Narrative: MY CREW WAS TASKED TO CHANGE THE #1 ENG ON AN MD11. THE ENG CONNECTORS WERE SECURED AND THE ENG PASSED INSPECTION AND POST CHANGE ENG RUN. THE NEXT DAY, #1 ENG ELECTRICAL PWR FROM THE IDG MALFUNCTIONED. THE IDG WAS REPLACED AND CHKED PER MAINT MANUAL. 2 DAYS LATER, MAINT AT XYZ FOUND ENG CONNECTORS SWAPPED. IF THESE CONNECTORS WERE SWAPPED INITIALLY, THEN THE PREVIOUS CHKS WOULD NOT HAVE WORKED. THE CONNECTORS WERE REMOVED AND REINSTALLED FOR TROUBLESHOOTING PREVIOUSLY. I DO NOT BELIEVE THAT MY CREW CROSSED THE CONNECTORS. AFTER EACH ENG CHANGE, THERE ARE SPECIFIC CHKS DONE BY LEAD AMT'S AND WITH INSPECTORS PRESENT. THESE CHKS WERE DONE TWICE BY DIFFERENT INDIVIDUALS. I BELIEVE THE CONNECTORS WERE REMOVED FOR TROUBLESHOOTING AFTER THE ENG CHANGE AND THEN REINSTALLED INCORRECTLY.
Data retrieved from NASA's ASRS site as of July 2007 and automatically converted to unabbreviated mixed upper/lowercase text. This report is for informational purposes with no guarantee of accuracy. See NASA's ASRS site for official report.