What happened
On February 4, 2003, a KLM Royal Dutch Airlines Boeing 747-40 and was prepared for a scheduled passenger flight from Amsterdam Airport Schiphol to Kuala Lumpur. During the takeoff roll on runway 24, the aircraft initially maintained the centerline despite strong, gusty winds. However, two seconds after reaching V1, the aircraft suddenly veered to the left. To prevent a full runway excursion, the pilot flying initiated rotation approximately 9 knots prior to VR. During this maneuver, the aircraft's left-hand gear struck a runway sign located just off the edge of the pavement. The impact caused a loud bang and significant vibrations felt by the crew. While the aircraft successfully became airborne, the incident resulted in two damaged tires on the left-hand body gear, which required replacement upon arrival in Kuala Lumpur.
The investigation
The investigation examined the flight preparation, weather monitoring, and cockpit procedures. It was discovered that the takeoff data card used by the crew contained incorrect wind information, likely due to an error when copying data from a discarded card. While the crew had received various ATIS reports, the most recent report (ATIS 'S') contained wind gust information that was not fully integrated into the crew's situational awareness. Furthermore, the investigation reviewed the flight data recorder, which showed that a sudden, large-scale left rudder input occurred at V1, causing the deviation. The investigation also looked into the company's specific crosswind limitations for wet runway operations.
Findings
- The takeoff crosswind component was approximately 33 knots, which exceeded the company's established limit of 25 knots for wet runway operations.
- There was a lack of crew awareness regarding the actual wind conditions, as the wind information on the takeoff data card was incorrectly recorded.
- The sudden deviation from the runway centerline was caused by a significant left rudder pedal input at the moment of V1.
- The crew's monitoring of the aircraft's position was hindered by the need to focus on fluctuating airspeed indications caused by the gusty conditions.
Safety action
While the investigation focused on the technical and procedural failures regarding wind limit awareness, the primary safety issue identified was the discrepancy between the actual wind conditions and the crew's operational knowledge of those limits during the takeoff phase.