AO-2024-031 Final
AO-2024-031 Final
Released in accordance with section 25 of the Transport Safety Investigation Act 2003
Publishing information
Published by: Australian Transport Safety Bureau
Postal address: GPO Box 321, Canberra, ACT 2601
Office: 12 Moore Street, Canberra, ACT 2601
Telephone: 1800 020 616, from overseas +61 2 6257 2463
Accident and incident notification: 1800 011 034 (24 hours)
Email: [email protected]
Website: www.atsb.gov.au
The CC BY 4.0 licence enables you to distribute, remix, adapt, and build upon our material in any medium or format,
so long as attribution is given to the Australian Transport Safety Bureau.
Copyright in material used in this report that was obtained from other agencies, private individuals or organisations,
belongs to those agencies, individuals or organisations. Where you wish to use their material, you will need to contact
them directly.
Addendum
Safety message
The ATSB advises King Air B200 operators and maintainers that in this incident, fatigue-related
fracture of a steering link in the nose landing gear system led to the landing gear becoming
inoperative. Although scheduled maintenance inspections required general inspection of the nose
steering parts, the inspections did not call for a detailed inspection for cracks.
This incident also highlights the value of aircraft system knowledge and resource management in
resolving malfunctions and in-flight emergencies. The pilot established that the available fuel
endurance allowed time to carefully consider the circumstances and attempted to resolve the
issue. They engaged company personnel to provide system troubleshooting information and
sought the assistance of the air traffic control personnel to inspect the aircraft.
The pilot also liaised with emergency services and prepared the passengers for the wheels-up
landing. This minimised the risk of injury and ensured the evacuation was conducted safely.
›i‹
ATSB – AO-2024-031
The investigation
Decisions regarding the scope of an investigation are based on many factors, including the level
of safety benefit likely to be obtained from an investigation and the associated resources
required. For this occurrence, a limited-scope investigation was conducted in order to produce a
short investigation report, and allow for greater industry awareness of findings that affect safety
and potential learning opportunities.
The occurrence
On the morning of 13 May 2024, a Beechcraft King Air B200, registered VH-XDV and operated by
Eastern Air Services, was being prepared for a multi-sector passenger transport flight from
Williamtown Airport, New South Wales. The flight was to transport 2 passengers from Williamtown
to Lord Howe Island, with an intermediate stop at Port Macquarie to collect an additional
6 passengers.
Both passengers boarded at Williamtown and at about 0830 local time the pilot taxied the aircraft
from the departure bay to runway 30. A passenger video recording captured the pilot’s actions and
cockpit area throughout the departure. No problems were identified with the aircraft during taxi.
The recording also identified that, as the pilot retracted the landing gear during the initial climb,
mechanical crunching noises were audible. As the aircraft continued to climb, the pilot
commenced a right turn and noted that the red indicator lights on the landing gear control handle
remained illuminated, signifying that the landing gear remained in transit or was not locked.
The pilot then contacted air traffic control (ATC) and reported a landing gear indication fault. The
pilot then cancelled their airways clearance to Port Macquarie and requested clearance from ATC
to remain in the Williamtown circuit to complete functional checks of the landing gear system.
The pilot was directed to operate in a southern circuit so that the aircraft would remain visible to
the tower controller. The controller visually identified that the landing gear was partially retracted,
which they conveyed to the pilot. In response, the pilot declared PAN PAN 1 and the controller
initiated the airport emergency plan. 2 Additional controllers were then called to the tower to help
manage the emergency.
1
Alert phase: a situation where apprehension exists as to the safety of an aircraft and its occupants (this generally
equates to a PAN PAN)
2
The Williamtown Airport emergency plan required on-base fire and ambulance services to respond within 30 seconds
of the base alarm being raised.
›1‹
ATSB – AO-2024-031
Figure 1: VH-XDV with landing gear partially retracted as it overflew Williamtown Airport
During a normal retraction cycle of the landing gear the nose wheel automatically centres.
Source: Department of Defence
The pilot maintained a holding pattern in the southern circuit over Williamtown Airport for
approximately 3 hours and 17 minutes. With rain approaching from the south, and a lowering
cloud base, the pilot’s desire to remain in visual meteorological conditions 3 and consume
additional fuel prompted them to track along the coastline to the north-east while the weather
passed (see Figure 2 and the section titled Pilot’s commentary of the emergency). Upon arrival
over Hawks Nest, ATC advised the pilot that the Williamtown Airport weather conditions had
improved.
While the pilot positioned the aircraft at the instrument approach waypoint 4 for Williamtown Airport,
the weather conditions deteriorated and the aircraft entered cloud and heavy rain. During this
period the pilot identified that on landing the fuel quantity onboard the aircraft may reduce below
the required final reserve. 5 ATC tower recordings identified that the pilot declared a MAYDAY
FUEL 6 at 1206.
At 1219 with the gear still jammed in the partially retracted position, the aircraft touched down on
runway 30 and came to a sliding stop after about 20 seconds. Airport rescue and firefighting and
other waiting services were then cleared to attend and entered the runway.
3
Visual Meteorological Conditions (VMC): an aviation flight category in which visual flight rules (VFR) flight is permitted –
that is, conditions in which pilots have sufficient visibility to fly the aircraft while maintaining visual separation from
terrain and other aircraft.
4
AKLOL was an initial approach fix (waypoint) for instrument navigation to Williamtown Airport.
5
A turbine-engine aircraft that is operated under the instrument flight rules is required to carry 45 minutes of fuel to allow
the aircraft to fly at holding speed, at 1,500 ft above the aerodrome elevation. This must be available at the completion
of the flight.
6
The declaration of a FUEL MAYDAY is an internationally recognised procedure associated with the standards of the
International Civil Aviation Organization and designed to assist in the management of aviation safety risks. As this is a
distress message, the aircraft will be given priority to land. Where the PIC has calculated that the aircraft will land with
less than the final reserve fuel, the flight crew must declare a situation of ‘emergency fuel’ by broadcasting MAYDAY
MAYDAY MAYDAY FUEL.
›2‹
ATSB – AO-2024-031
No injuries were sustained by the pilot or passengers on board. The aircraft sustained minor
damage from the landing incident and there was no fire.
Figure 2: VH-XDV completed numerous circuits at Williamtown before transiting to
Hawks Nest, then returning to Williamtown
The aircraft track was obtained from the automatic dependent surveillance-broadcast data transmitted from the aircraft.
Source: Google Earth, annotated by the ATSB
Context
Aircraft information
The Beechcraft King Air B200 is a pressurised, low-wing, twin turbine-engine aircraft with
retractable landing gear. The aircraft had a certified maximum take-off weight of
5,670 kg and could be flown by a single pilot. The aircraft, serial number BB-1100, was
manufactured in the United States in 1982 and subsequently registered in Australia in 2008.
Eastern Air Services had been the registered operator of the aircraft since February 2018.
damper remained clear of all components of the wheel bay area. They further identified that the
shimmy damper could only contact the wheel bay area if the nose wheel became mechanically
disconnected from the steering system. That disconnection enabled the nose wheel to rotate left
beyond its operational limit sufficiently for the shimmy damper to contact the undercarriage door
bay area during the nose gear retraction sequence.
The operator advised that there were no binding or other defects present in the remainder of the
steering or landing gear components fitted to the aircraft. The operator also found that once the
circuit breakers were reset, the landing gear system became electrically functional, allowing the
gear to lower. One of those required circuit breakers was not accessible to the pilot in flight.
Figure 3: The nose landing gear tilted to the left with the shimmy damper jammed against
a hinge in the undercarriage bay
›4‹
ATSB – AO-2024-031
Should the landing gear fail to extend, the next steps in the procedure stated:
If one or more green gear-down annunciators do not illuminate for any reason and a decision is made
to land in this condition:
7. Alternate Extension Handle – CONTINUE PUMPING UNTIL MAXIMUM RESISTENCE IS FELT,
EVEN THOUGH THIS MAY DAMAGE THE DRIVE MECHANISM
8. Landing Gear Controls – DO NOT ACTIVATE
›5‹
ATSB – AO-2024-031
Nose wheel steering is through direct mechanical actuation of the linkages in the system from the
rudder pedals that connect to an arm near the top of the nose gear shock strut (Figure 5). A spring
mechanism in the steering barrel dampens the transmission of excessive shock loads to the
rudder pedals. A strut-mounted roller engages with a centring ramp to automatically centre the
nose wheel during retraction of the gear.
Figure 5: King Air B200 nose steering system schematic
Aircraft maintenance
Scheduled maintenance for VH-XDV was based on a 200-hour phased inspection program, the
details of which were specified by the aircraft manufacturer and contained within the King Air B200
maintenance manual. The operator’s maintenance records identified that a Phase-4 check was
completed on 18 March 2024 at 18,298.4 hours. During that check the landing gear system was
overhauled. Parts relating to the nose wheel steering were inspected but not replaced as their
continued serviceability was based ‘on-condition’, rather than having a prescribed ‘life-limit’. On
that basis the service life of the steering link was not required to be tracked and its service history
was unable to be established.
The Phase-4 inspection requirements listed in the maintenance manual for the nose gear
components were non-specific and all parts were to be inspected for ‘wear damage and surface
corrosion.’ For the steering linkage, it was required to be:
STEERING LINKAGE - Inspect nose gear steering mechanism and attaching hardware for wear,
damage and corrosion..
There was no specific requirement to inspect the steering link for cracks.
Pilot information
The pilot held an air transport pilot licence (aeroplane), issued in September 2015, with a
multi-engine aeroplane instrument rating. In addition, they held a current grade 1 flight instructor
rating and a multi-engine class flight test examiner rating. They reported approximately
8,500 hours total flying experience, of which 2,500 hours were accrued on the King Air B200.
›6‹
ATSB – AO-2024-031
Williamtown weather
When the aircraft was initially directed to the Williamtown southern circuit, the ATC controller
estimated that the cloud base was between 2,000 ft and 2,500 ft AGL. Meteorological
observations at Williamtown Airport identified that from 1130 through to 1400, rain showers and
drizzle persisted. The ATC controller reported that during that period the cloud base began to
lower, making it difficult to sight the aircraft.
In the minutes prior to the wheels-up landing, the meteorological observations indicated visibility
greater than 10 km, drizzle in the vicinity of the airport, and a cloud amount of 1–2 oktas 8 at
1,300 ft AGL.
7
Instrument meteorological conditions (IMC): weather conditions that require pilots to fly primarily by reference to
instruments, and therefore under instrument flight rules (IFR), rather than by outside visual reference. Typically, this
means flying in cloud or limited visibility.
8
Cloud amount is given in the international standard format. The terms used are FEW (few) to indicate 1–2 oktas, SCT
(scattered) to indicate 3–4 oktas, BKN (broken) to indicate 5–7 oktas, OVC (overcast) to indicate 8 oktas.
›7‹
ATSB – AO-2024-031
Chapter 18 of the Handbook, Emergency Procedures, provides generic advice to pilots for
performing a gear up landing. The Handbook advised pilots to:
• select an airport with fire and rescue facilities
• request emergency equipment to stand by
• select a smooth, hard runway surface rather than an unimproved grass strip
• consider burning off excess fuel to reduce fire potential
• consider that the safest course of action may be to land with all three gears in the retracted
configuration.
›8‹
ATSB – AO-2024-031
Source: ATSB
Figure 7: Microscopic striations (arrowed) were identified on the steering link fracture
surface within the region of the pre-existing defect
The above image was captured using a scanning electron microscope at x4,500 magnification
Source: ATSB
›9‹
ATSB – AO-2024-031
Other occurrences
The ATSB's aviation occurrence database was searched for landing gear malfunctions leading to
a wheels-up landing involving King Air B200 aircraft between 2014–2024. No such instances were
identified. There were, however, 130 records of a wheels-up landing for all aircraft types, none of
which resulted in injuries or fire.
The review of occurrence database records also identified 92 reports of 'gear unsafe' indications
for the King Air B200. There was a broad range of reasons attributed for those indications,
however, none of them led to a wheels-up landing. There were 12 instances where the
emergency manual extension was required to be utilised and in each of those the landing gear
was able to be extended.
Additionally, the aircraft manufacturer (Textron Aviation) advised that it was not aware of other
instances of this specific malfunction where the mechanical landing gear became jammed leading
to a wheels-up landing. It was also unaware of other instances where fatigue cracks had been
identified in steering links.
› 10 ‹
ATSB – AO-2024-031
Safety analysis
The ATSB identified that the aircraft was able to be steered by the pilot using the rudder pedals as
it was taxied to the departure runway and during the take-off roll. This indicated that the nose
wheel steering system, including the steering linkage, was intact during the taxi and the initial
stage of the take-off roll.
ATSB’s laboratory examination of the steering components identified the presence of a fatigue
crack on the fracture surfaces of the steering link that had initiated from a surface flaw. The
pre-existing, high-cycle fatigue crack was small in comparison to the overall steering link cross
section, indicating that the final fracture likely occurred over a relatively short number of loading
cycles.
The nature of the loading that resulted in the final fracture was not identified. However, casting
alloys are generally regarded as having relatively low fracture toughness when compared with
wrought alloys, predisposing them to brittle fracture. Additionally, it is generally the case that the
increase in stress intensity from a pre-existing fatigue crack will lead to fracture at much lower
stresses due to the inherently low fracture toughness of a casting alloy.
As the pilot was able to conduct the take-off without issue, the fracture of the steering link must
have occurred either late in the take-off roll or as the gear was retracted. Once the steering link
fractured, the nose wheel was able to rotate beyond its normal operational limits. In this instance,
the nose wheel rotated significantly to the left. That movement led to the nose gear shimmy
damper also rotating beyond normal limits sufficiently to become jammed against a door hinge
within the nose wheel well.
When the pilot consulted the procedures for a manual gear extension, their efforts were ineffectual
because the shimmy damper had mechanically jammed the operation of that system. Despite
numerous attempts, the pilot was subsequently unable to extend the landing gear using the
published emergency extension procedure, necessitating a wheels-up landing.
› 11 ‹
ATSB – AO-2024-031
Findings
ATSB investigation report findings focus on safety factors (that is, events and conditions that
increase risk). Safety factors include ‘contributing factors’ and ‘other factors that increased risk’
(that is, factors that did not meet the definition of a contributing factor for this occurrence but
were still considered important to include in the report for the purpose of increasing awareness
and enhancing safety). In addition ‘other findings’ may be included to provide important
information about topics other than safety factors.
These findings should not be read as apportioning blame or liability to any particular
organisation or individual.
From the evidence available, the following findings are made with respect to the wheels-up
landing involving a Beechcraft King Air B200, VH-XDV, at Williamtown Airport, New South Wales
on 13 May 2024.
Contributing factors
• During the take-off roll or landing gear retraction sequence, the steering link fractured from a
pre-existing fatigue crack, resulting in a mechanical disconnect within the nose landing gear
steering system.
• When the landing gear retracted, the fractured steering link allowed the nose gear shimmy
damper to contact the side of the wheel well and jam the nose landing gear in a partially
retracted position. This prevented extension of the landing gear using the published
emergency procedure, necessitating a wheels-up landing.
Safety actions
Whether or not the ATSB identifies safety issues in the course of an investigation, relevant
organisations may proactively initiate safety action in order to reduce their safety risk. All of the
directly involved parties are invited to provide submissions to this draft report. As part of that
process, each organisation is asked to communicate what safety actions, if any, they have
carried out to reduce the risk associated with this type of occurrences in the future. The ATSB
has so far been advised of the following proactive safety action in response to this occurrence.
› 12 ‹
ATSB – AO-2024-031
General details
Occurrence details
Date and time: 13 May 2024 – 1219 Eastern Standard Time
Occurrence class: Serious incident
Occurrence categories: Wheels up landing, Fuel dump/burn off, Landing gear / Indication
Location: Williamtown Airport, New South Wales
Latitude: 32.7950° S Longitude: 151.8344° E
Aircraft details
Manufacturer and model: Beechcraft King Air B200
Registration: VH-XDV
Operator: Eastern Air Services
Serial number: BB-1100
Type of operation: Part 135 Australian air transport operations - Smaller aeroplanes
Activity: Commercial air transport - Scheduled-Domestic
Departure: Williamtown Airport, New South Wales
Destination: Lord Howe Island, New South Wales
Actual destination: Williamtown Airport, New South Wales
Persons on board: Crew – 1 Passengers – 2
Injuries: Crew – none Passengers – none
Aircraft damage: Minor
› 13 ‹
ATSB – AO-2024-031
References
United States Federal Aviation Administration, Airplane Flying Handbook FAA-H-8083-3C
Beechcraft King Air B200 Maintenance Manual
Beechcraft King Air B200 Pilot’s Operating Handbook
Submissions
Under section 26 of the Transport Safety Investigation Act 2003, the ATSB may provide a draft
report, on a confidential basis, to any person whom the ATSB considers appropriate. That section
allows a person receiving a draft report to make submissions to the ATSB about the draft report.
A draft of this report was provided to the following directly involved parties:
• the pilot of VH-XDV
• Eastern Air Services
• Royal Australian Air Force – 453 Squadron
• Textron Aviation
• Civil Aviation Safey Authority
Submissions were received from:
• the pilot of VH-XDV
• Eastern Air Services
• Royal Australian Air Force – 453 Squadron
The submissions were reviewed and, where considered appropriate, the text of the report was
amended accordingly.
› 14 ‹
ATSB – AO-2024-031
Terminology
An explanation of terminology used in ATSB investigation reports is available on the ATSB
website. This includes terms such as occurrence, contributing factor, other factor that increased
risk, and safety issue.
› 15 ‹