Left Main Landing Gear Collapse Causes Substantial Damage to Douglas DC-9

Casualties unknown • Tokunoshima Airport, JP

A Japan Air System flight experienced a left main landing gear collapse during rollout at Tokunoshima Airport, leading to wingtip contact with the runway.

What happened

On January 1, 2004, a Japan Air System (JAS) Douglas DC-9-81, registration JA8297, was operating a scheduled passenger flight from Kagoshima Airport to Tokunoshima Airport. The flight, operated by Harlequin Air, departed Kagoshima at 15:35 JST.

Upon landing at Tokunoshima Airport, the aircraft's left main landing gear collapsed during the landing roll. This structural failure caused the fuselage to tilt to the left, resulting in the left wingtip making contact with the runway surface. The aircraft continued along the runway before coming to a complete stop at approximately 16:2 and 24 JST. While the aircraft sustained significant damage—including damage to the left engine fan blades and the left wing structure—there were no fatalities among the 169 people on board. Three passengers sustained minor injuries during the incident.

The investigation

The investigation focused on the mechanical failure of the left main landing gear cylinder. Investigators examined the aircraft's flight data recorder (DFDR) and cockpit voice recorder (CVR), as well as maintenance records and the physical wreckage.

Technical analysis involved a detailed examination of the landing gear cylinder by the aircraft manufacturer and specialized research into the cylinder's surface condition. The investigation scrutinized the history of the specific landing gear component, which had been installed on JA8297 in April 2000 following an overhaul. Researchers also investigated the effects of the grit-blasting process used during the plating of the cylinder and the presence of micro-cracks within the metal structure.

Probable cause

The collapse of the left main landing gear cylinder was caused by the growth of micro-cracks in the cylinder's fuse section. These cracks were initially generated by stresses from 'gear walks' that occurred before a hydraulic restrictor was installed. The progression of these cracks was further facilitated by surface flaws resulting from the grit-blasting process. Additionally, the manufacturer's failure to establish adequate inspection intervals prevented the detection of this fatigue cracking during routine maintenance.

Frequently asked questions

What happened in the 2004-01-01 Douglas DC-9-81 accident near Tokunoshima Airport, JP?

A Japan Air System flight experienced a left main landing gear collapse during rollout at Tokunoshima Airport, leading to wingtip contact with the runway.

What aircraft was involved and where did it happen?

The accident on 2004-01-01 involved a Douglas DC-9-81, registration JA8297, operated by Japan Air System, at Tokunoshima Airport, JP.

What was the probable cause of the accident?

The collapse of the left main landing gear cylinder was caused by the growth of micro-cracks in the cylinder's fuse section. These cracks were initially generated by stresses from 'gear walks' that occurred before a hydraulic restrictor was installed. The progression of these cracks was further facilitated by surface…

Investigation report by the Japan Transport Safety Board (JTSB). Original record: https://jtsb.mlit.go.jp/eng-air_report/JA8297.pdf. This page is a structured re-presentation; facts and quotes are in the Japan Transport Safety Board (JTSB) - Ministry of Land, Infrastructure, Transport and Tourism.

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