Nose Gear Failure Due to Maintenance Error and Switch Misadjustment

Casualties unknown • San Juan, PR, US

Aircraft landed on a partially retracted nose gear after the unsafe light remained on. Investigation found a misadjusted microswitch and use of an incorrect maintenance manual prevented proper inspection.

What happened

Following takeoff, the pilot observed that the nose gear unsafe indicator light remained illuminated despite initiating the gear retraction sequence. Subsequent attempts to confirm the nose gear was safely locked in the extended position were unsuccessful. The aircraft continued its flight and landed with the nose landing gear in a partially retracted state, resulting in the strut settling onto the runway.

The investigation

Post-accident examination of the airframe revealed that the nose gear strut had not achieved full extension prior to the landing impact. During the retraction cycle, the nose gear tires made contact with the nose gear doors, physically preventing them from opening fully. This obstruction caused the gear to retract against the closed doors, leading to a mechanical failure of the retract jackscrew.

Further inspection identified that a critical microswitch, designed to cut power to the gear motor when such an obstruction occurs, was found out of adjustment and failed to operate. The investigation determined that the mechanics performing the last gear retraction test had utilized a maintenance manual for an earlier aircraft model. This older manual did not include procedures for checking this specific safety switch, resulting in the oversight.

Findings

The failure to extend the nose gear fully was attributed to a combination of mechanical obstruction and inadequate maintenance procedures. The primary contributing factors included:

  • Failure of the retract jackscrew due to retraction against closed doors.
  • Misadjusted microswitch that failed to stop the gear motor during the obstruction.
  • Use of an incorrect maintenance manual by mechanics, which omitted the necessary check for the safety switch adjustment.

No mechanical reason was found for why the nose gear strut initially failed to fully extend. The root cause lay in the maintenance error and the subsequent failure of the safety mechanism to detect the jammed condition.

Probable cause

The pilot's failure to ensure the nose gear was fully extended, likely due to a misadjusted microswitch that failed to cut off the gear motor when the gear retracted against the doors. Contributing factors included the use of an incorrect maintenance manual by mechanics who failed to check the switch adjustment.

Frequently asked questions

What happened in the 1985-06-24 Mitsubishi MU-2K accident near San Juan, PR?

Aircraft landed on a partially retracted nose gear after the unsafe light remained on. Investigation found a misadjusted microswitch and use of an incorrect maintenance manual prevented proper inspection.

What aircraft was involved and where did it happen?

The accident on 1985-06-24 involved a Mitsubishi MU-2K, registration N7DD, operated by Executive Airline & Charter, at San Juan, PR.

What was the probable cause of the accident?

The pilot's failure to ensure the nose gear was fully extended, likely due to a misadjusted microswitch that failed to cut off the gear motor when the gear retracted against the doors. Contributing factors included the use of an incorrect maintenance manual by mechanics who failed to check the switch adjustment.

Investigation report by the U.S. National Transportation Safety Board (NTSB) historical archive. Original record: https://carol.ntsb.gov/event/20001214X36843. This page is a structured re-presentation; facts and quotes are in the National Transportation Safety Board (NTSB), United States.

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