No immediate action required after DHL 757 lands with open cargo door

A 757-200PCF (25620) operated by U.K.-based DHL Air returned to Leipzig (LEJ) minutes after take-off on Feb. 13, with the main cargo door in full-open position. The aircraft landed safely with no reported injuries, cargo losses or major structural damage to the aircraft reported, although the fiberglass lining was torn off the interior of the door. While unit 25620 is currently still at LEJ, DHL’s other 757-200PCFs — as well as those with other operators around the world — have continued to fly. Neither the European Union Aviation Safety Agency (EASA) nor the Federal Aviation Administration (FAA) have issued any applicable airworthiness directives since the incident. [caption id="attachment_415401" align="alignright" width="560"] DHL has a fleet of more than thirty 757-200Fs. (Photo/DHL Express)[/caption] Precision Aircraft Solutions, which converted the aircraft to freighter configuration in 2011, is not recommending any operator action at this time, according to a bulletin sent to operators and seen by Cargo Facts . Precision told Cargo Facts it has dispatched a technical advisor to support the German Federal Bureau of Aircraft Accident Investigation (BFU) as it investigates the cause of the incident. It is also working with the operator to provide a repair assessment to return the aircraft to service. Most modern freighter conversions, including the 757-200PCF, are equipped with indicator systems and safeguards to alert flight crews to issues with the cargo door prior to, or during take off. While each regulator’s requirements for these warning systems are similar, subtle differences exist between FAA requirements, and EASA requirements. According to EASA’s Certification Specifications and Acceptable Means of Compliance for Large Aeroplanes (CS-25), there must be “a visual means on the flight deck to signal the pilots if any door is not fully closed, latched, and locked.” There must also be “an aural warning to the pilots prior to or during the initial portion of take-off roll if any door is not fully closed, latched, and locked, and its opening would prevent a safe take-off and return to landing.” Similarly, Part 25 of the Federal Aviation Regulations also states that there must be a visual means and an aural warning, but additionally says that the visual means “may be a simple amber light or it may need to be a red warning light tied to the master warning system, depending on the criticality of the door,” while “a more conspicuous aural warning is needed in addition to the visual indication” if an unlatched door could open and prevent a safe takeoff and return to landing. Precision confirmed to Cargo Facts that the aircraft is equipped with the required door status indication systems and in compliance with EASA service bulletins related to door status indication systems. Leipzig saw snow and frigid conditions last week and inclement weather has not yet been ruled out as a contributing factor. DHL declined to comment on specifics, confirming only that “during the flight lightweight parts of an aircraft cargo door frame were torn off.” A spokesperson for EASA told Cargo Facts , “At this stage it is too early to draw any conclusions.” In December 2014, a 757-200PCF (25597) operated by Russia-based Yakutia Airlines also made an emergency landing in Magadan (GDX) with the main cargo door fully open. Ice and compressed snow were found in and around the door’s locking mechanism after landing. In that incident, the aircraft had been on the ground for around eight hours in snowy conditions, with “periodic opening and closing” of the cargo door, according to a letter by the Russian Federal Air Transport Agency . Cargo Facts Asia, taking place April 20-21 as a virtual experience, is the event for exploring opportunity in the Asia-Pacific region. The event continues to bring together the best, brightest, and most innovative executives in the global air cargo industry. Learn more and register at www.cargofactsasia.com .

No immediate action required after DHL 757 lands with open cargo door

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