TOLEDO, OH, USA
N794AL
DOUGLAS DC-8-63
THE MAIN CARGO DOOR OPENED IN FLIGHT AND THE AIRPLANE RETURNED FOR A NORMAL LANDING. OF THE TWO CIRCUIT BREAKERS REQUIRED TO BE PULLED PRIOR TO TAKEOFF, ONE WAS FOUND STILL ENGAGED. A CONFORMITY INSPECTION ON THE CARGO DOOR INSTALLATION REVEALED SEVERAL AREAS OF NONCONFORMITY INCLUDING DOOR LOCKS OF LESS THAN REQUIRED STRENGTH, LACK OF PAINT ON DOOR LOCKS WHICH IS USED FOR VISUAL IDENTIFICATION, AND DAMAGED WIRES IN A BUNDLE. THE WIRES WERE PART OF THE DOOR CLOSING, DOOR LOCKED INDICATING SYSTEM. THE INVESTIGATION REVEALED IT WAS POSSIBLE FOR THE DOOR TO BE NOT COMPLETELY CLOSED AND HAVE THE DOOR WARNING LIGHT GO OUT, INDICATING IT WAS FULLY LOCKED.
THE FAILURE OF THE FLIGHT ENGINEER TO CONDUCT A PROPER PREFLIGHT INSPECTION AND ENSURE THE MAIN CARGO DOOR WAS FULLY CLOSED AND LOCKED. FACTORS RELATED TO THE ACCIDENT WERE THE DAMAGED WIRES IN THE BUNDLE, AND THE IMPROPER MAIN CARGO DOOR INSTALLATION.
Source: NTSB Aviation Accident Database
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