In the past three months, there have been two incidents involving older paraglider harnesses equipped with CLICK-LOCK buckles (HSi10) in the chest strap. The buckles had opened unintentionally during flight while they were under load. In one of the cases this happened during a SAT maneuver (spreading of the chest strap due to the pilot resting on the riser), in the other case the reason was presumably the load applied by the body weight of the pilot who was hanging only in the leg straps.

Finsterwalder has conducted a technical investigation and found the following:
The hooks of the metal tongue can wear out through the frequent diagonal load changes the chest strap is subject to. This might lead to decreased load capacity and – in the case of sufficiently high diagonal load transmission – the buckle might open unintentionally.
As a consequence of this finding, Finsterwalder has limited the respective buckles’ service time to 4 years if they are used in paraglider chest straps. The harness manufacturers have already been informed accordingly.

To date, there have been no unintentional openings of T-LOCK buckles. However, since their mechanism resembles that of CLICK-LOCK buckles, the problem is likely to be the same.

Finsterwalder calls on all owners of harnesses equipped with CLICK-LOCKs (HSi10) or T-LOCKs in the chest strap to determine their buckles’ previous usage time by checking the routine test date on the sample inspection label. If this date indicates a usage time of more than 4 years, the harness is not airworthy for now and may not be used for flying anymore. Affected owners should contact their harness manufacturer.

The service time limitation applies only to CLICK-LOCK and T-LOCK buckles that are used in paraglider chest straps. When used for applications where only static loads are involved, the CLICK-LOCK and T-LOCK buckles’ service life is 10 years.

The following harness manufacturers have used the mentioned buckles in one or more of their models: Advance, AVA Sport, APCO, Finsterwalder & Charly, KARPO FLY, SKY Paragliders, SkyTrekking, SOL, Woody Valley. Besides the buckles are used in paramotor harnesses of several manufacturers.

Finsterwalder GmbH
Pagodenburgstr.8,
81247 München

The following ADVANCE products are fitted with these types of chest strap buckles:

• ADVANCE PRO 2+, Hsi68 T-LOCK (DHV GS-03-0273-03)
• ADVANCE IMPRESS, Hsi17 CLICKLOCK
• ADVANCE IMPRESS 2, Hsi17 CLICKLOCK
• ADVANCE IMPRESS 2+, Hsi17 CLICKLOCK (EAPR-GZ-7072/08)
• ADVANCE SUCCESS, Hsi68 T-LOCK
• ADVANCE SUCCESS 2+, Hsi17 CLICKLOCK (EAPR-GZ-7034/08)

March 2016

Glass Fuel Filter Failure

Airborne XT-912 (2005) TSN 680hrs.

Original Fuel Filter: Filter failure was found during an annual service, approx. 13 days after aircraft was last flown.

There appears to be fatigue of the alloy die cast core. Alloy break showed many air bubbles in the casting.

Airborne have been informed and we are awaiting feedback regarding their findings.

Broken Wheel Spat Bracket

1). Airborne XT-912 (2005) TSN 680hrs.
2). Airborne XT-912 (2005) TSN 405.16hrs:

Pre-Flight Inspection: Give the wheel spats a gentle shake from side to side to check for any movement. If any movement is noticed, check this bracket for signs of cracking. File a defect report via the HGFA website or contact the HGFA WM Technical Manager or HGFA Operations Manager with details.

Cracked RH Wing Adjuster Webbing Cap

Airborne XT-912 Tourer (2005) TSN 376hrs.:  Stress crack radiating from the securing screw (IPC Item 10, part # 105140) found during post flight inspection. Both LH and RH leading edge tensioner assemblies (part #s 104669 and 104740) were replaced with new style parts purchased and supplied by Airborne.  2 x test flights subsequently conducted to confirm wing tuning settings.

September 2015

Hinge Batten Fitting Security - Airborne Windsports Wings

Status: Active

Issue Date: 01-09-2015

Issued By: Rick Duncan

Applicability: All Airborne Windsports Wings

Compliance: 100 Hourly line maintenance

Reference: Material Airborne Engineering Report 15/025/DS

Hinge Batten Fitting Security SB-019

August 2015

Malibu bottom upright fitting wire wear issue

Applies from: 17th August, 2015

Applies to: Any Moyes glider using round uprights.

Inspection: Whenever an upright is broken or bent it may cause damage to the top and bottom upright fittings, these parts should be inspected closely and replaced at any sign of wear or damage.

Service Requirement: Replace bottom upright fitting after 300 hours or if wire slot widens to greater than 4.8 mm.

It has been bought to our attention of a potential problem of the bottom upright fitting on gliders with round uprights.
The wear has occurred on the slot where the ball swage fits into.

The photo shows a fitting from a glider with 600+ hours airtime where the slot has been worn and widened.

The photo shows a broken fitting from a training glider.

It is now mandatory to replace the fitting
when the opening exceeds 4.8mm or after 300 hours airtime.

January 2015

Defect Report #8: Airborne XT-582 - Part No. 106910 Bracket Intake Silencer XT582 Rear.

Aircraft Type: Airborne XT-582

Inspection recommended - Prior to next flight and subsequently after every flight.
The bracket needs to be thoroughly inspected for cracks.

Defect: Reports of cracking of the air intake silencer rear mounting bracket. Airborne have increase the length of the bracket as the original one was too short.

If cracking is found, please contact Airborne directly.

Resolved: Airborne have increased the length of the bracket.

Defect Report #7: Airborne XT-912 - Engine/oil cooler mount brackets.

Aircraft Type: Airborne XT-912B

Inspection recommended - Prior to next flight and subsequently after every flight.
The brackets needs to be thoroughly inspected for cracks.

Defect: Reports of cracking of the engine/cooler mounting brackets where the nut has been tightened onto a step in the bracket causing undue stress in that location.

If cracking is found, please file a WM Defect Report on the HGFA website.

Airborne have been made aware of this issue and are supplying replacement brackets.
The engine mount bolts torque value will be added to their next manual update.

Please be aware that when installing the new Engine Brackets, the following Torques need to be applied:

Top Link bolt (part number 105515):  6mm bolt. Torque 10Nm  

Engine mount bolts (part number: 105944) x 4:  10mm bolt.  Torque 50Nm, apply Loctite 243

For specific torques on oil cooler fittings and exhaust manifold refer to Rotax 912 Illustrated Parts Catalogue.

Reinstallation of exhaust components should be done iaw the Aircraft Maintenance Manual, taking care to tighten the manifold nuts evenly to ensure that no stress is put on the manifold, which could induce cracking

Defect Report #6: Airborne XT-912 - Plastic Fuel-cock handle.

Aircraft Type: Airborne XT-912 Rotax 80hp

Inspection recommended - Prior to next flight, carry out a functional check of the fuel cock as part of pre-flight inspection. Remove and inspect handle for rounding or cracking.

Defect: Fuel shut off valve handle was moved from off to on position and on engine start up the engine ran for 10 to 12 sec before it shut down. Inspection found the fuel shut off valve was in the "off" position whilst the handle showed the "on" position.

If rounding or cracking is found, please file a WM Defect Report on the HGFA website.

Airborne have been made aware of this issue and we await their response. We will publish findings/corrective action when received.

June 2009

582 Oil Filter Bracket Failure

Reports are being received regarding the Oil Filter Bracket on Airborne 582 aircraft. There does not seem to be any report of similar failures on any other model or make. Airborne have been made aware of this issue and we await their comment in response to the issue.

The upper half segment of the two stroke oil tank mounting bracket is noted to crack (see picture) . This fracture is in the 90 degree radius bend, adjacent to the three cylinder head bolts / isolator mounts that provide sole support for this assembly.