Cargo Door Light Illumination Precedes Pressurization Loss During Departure (N416DA)

Event Description

Following a normal pushback and taxi to the runway, the airplane commenced a takeoff. During the takeoff roll, the aft cargo door light on the second officer's panel illuminated. The decision was made to continue the takeoff. After climbing approximately 900 feet, an audible pop was heard and pressurization was subsequently lost. The pilot elected to return to the departure airport and landed without further incident.

Examination Findings

A subsequent examination of the cargo door system revealed that the door latch mechanism should have functioned properly under normal circumstances. Additionally, the cargo door light was designed to illuminate if the door was not closed. Investigation further disclosed that none of the ground crew members could recall latching the cargo door prior to departure. The post-flight inspection determined that the door latch system was in proper working order and that the illumination of the cargo door light was consistent with the door not being secured. Furthermore, it was established that no ground crew member remembered performing the latching procedure. The aircraft returned to service after corrective actions were taken.