The U.S. Federal Aviation Administration (FAA) has issued a safety advisory urging operators of Boeing 757-200 converted freighters to perform rigorous cargo door inspections. The recommendation follows a serious incident in February 2021, when a DHL Air aircraft experienced a cargo door failure mid-flight during ascent from Leipzig, Germany, leading to an emergency return.
Background and Safety Concerns
In the Leipzig incident, the crew detected a sudden loss of cabin pressure, yet no cockpit warning indicated a door malfunction. Investigations revealed that the hydraulically-operated cargo door, modified by Precision Conversions, had failed despite proximity sensors designed to confirm proper locking and latching.
This incident is not isolated. In December 2014, a Yakutia Airlines Boeing 757-200 freighter suffered a similar cargo door malfunction due to ice accumulation after prolonged exposure to extreme cold in Magadan, Russia. Additionally, the European Union Aviation Safety Agency (EASA) issued a warning in June 2023 regarding potential door malfunctions in passenger-to-freighter conversions.
FAA’s Recommendations for Airlines
While the FAA has not issued a mandatory airworthiness directive, it has provided strong recommendations for airlines operating converted 757 freighters:
- Routine Cargo Door Testing: Operators should perform ‘door-open’, ‘door-closed’, and ‘latched and locked’ tests every 5,000 flight cycles, as specified in Precision Conversions’ maintenance manual.
- Thorough Visual Inspections: Aircraft maintenance teams should inspect:
- View-port mirrors and windows for smudges or debris that might obstruct safety checks.
- Latches and lock pins for paint defects or mechanical wear, repainting them as needed.
- Enhanced Cold Weather Protocols: Given past failures in icy conditions, airlines should:
- Remove ice and snow from cargo door mechanisms before departure.
- Conduct additional inspections in freezing fog or heavy icing conditions.
Industry Response and Implications
Although the FAA bulletin does not ground Boeing 757 freighters, it signals heightened scrutiny over cargo door reliability. Airlines operating these aircraft must now reinforce their maintenance protocols to prevent similar failures.
With Boeing 757 freighters playing a critical role in global cargo operations, ensuring compliance with these recommendations will be vital to maintaining safety and operational efficiency.
For ongoing updates on aviation safety and logistics developments, stay tuned to The Logistic News.
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