Incident Overview

Date: Friday 3 March 2017
Aircraft Type: Airbus A320-214
Owner/operator: easyJet
Registration Number: G-EZTV
Location: Manchester Airport (MAN) – ÿ United Kingdom
Phase of Flight: Pushback / towing
Status: Substantial, repaired
Casualties: Fatalities: 0 / Occupants: 178
Component Affected: The TowbarThe Towbar
Investigating Agency: AAIBAAIB
Category: Accident
On March 1, 2023, a scheduled JetStar flight from Manchester Airport to Copenhagen, Denmark, was cancelled due to a tow truck incident involving a towbar. A tow truck jack-knifed and became lodged under the aircraft’s fuselage, causing a jolt and mechanical clunk. The commander, relying on visual inspection and crew communication, assessed the situation. The left engine was initiated, though the aircraft hadn’t reached its designated start position. The tug driver, guided by the headset operator, directed the aircraft to start the right engine. Following a request from the commander, the left engine was activated, and the aircraft began to move gently forward. The tug and headset operator were concealed, and the aircraft’s nose turned to the right, then to the left, indicating a misalignment. The tug and aircraft collided, with the nose gear rotating 90 degrees to the left, and the towbar bending around the front corner of the tug. Shear pins on the towbar fractured, and pieces were found within the stand. The incident was investigated, revealing a pre-existing pin failure of 16 days prior, and inadequate lubrication and training procedures for serviceability checks. The investigation did not identify a probable cause.On March 1, 2023, a scheduled JetStar flight from Manchester Airport to Copenhagen, Denmark, was cancelled due to a tow truck incident involving a towbar. A tow truck jack-knifed and became lodged under the aircraft’s fuselage, causing a jolt and mechanical clunk. The commander, relying on visual inspection and crew communication, assessed the situation. The left engine was initiated, though the aircraft hadn’t reached its designated start position. The tug driver, guided by the headset operator, directed the aircraft to start the right engine. Following a request from the commander, the left engine was activated, and the aircraft began to move gently forward. The tug and headset operator were concealed, and the aircraft’s nose turned to the right, then to the left, indicating a misalignment. The tug and aircraft collided, with the nose gear rotating 90 degrees to the left, and the towbar bending around the front corner of the tug. Shear pins on the towbar fractured, and pieces were found within the stand. The incident was investigated, revealing a pre-existing pin failure of 16 days prior, and inadequate lubrication and training procedures for serviceability checks. The investigation did not identify a probable cause.

Description

EasyJet flight 1985, a scheduled service from Manchester, U.K. to Copenhagen, Denmark, was cancelled after a tow truck jack-knifed and became stuck under the aircraft’s fuselage. During the pushback from Stand 1 at Manchester Airport, in dark and wet conditions, the flight deck crew felt a fore and aft jolt and heard a mechanical “clunk”. The commander informed the headset operator who conferred with the tug driver, and then visually checked the towbar and its attachment to the tug and to the aircraft. The ground crew saw nothing abnormal and they assumed the clunk was due to the tow hitch shifting, which is a familiar occurrence. The headset operator informed the commander that all was well, and the pushback continued. In response to a request from the commander, the headset operator indicated the left engine could be started, although the aircraft had not reached the designated engine start positon for that stand. As the aircraft was halted, in preparation for being pulled forward to the release point, the headset operator approved a request from the flight deck crew to start the right engine. The commander was conscious of the aircraft beginning to move gently forward, while he was concentrating on starting the right engine. Both the tug and the headset operator were concealed from his field of view and he was not surprised when the aircraft’s nose turned first to the right and then to the left, as if it was being lined-up on the taxiway centreline. He then heard an urgent instruction from the headset operator for the brakes to be applied, so he responded by pressing on the toe brakes before setting the park brake. The headset operator then informed him that the tug and aircraft had collided, but that nobody was injured. Both engines were then shut down. Ground crew from adjacent stands came to assist and found the towbar was still connected to both the tug and to the aircraft. The nose gear leg was rotated approximately 90ø to the left and the tow bar was bent around the front corner of the tug. The shear pins on the towbar had fractured, and pieces were later found within the boundary of the stand, but the central retaining pin remained intact. The passengers and crew disembarked without injury from the rear right exit door. An investigation by the ground handling company showed One of the pins on this towbar had failed 16 days before the accident and only that pin had been replaced. It was also established that other maintenance procedures for the shear pins had not been followed. They had not been lubricated correctly and the training given to ground crews did not prepare them for conducting adequate serviceability checks on the pins. No Probable Cause was issued by the AAIB

Primary Cause

Pre-existing shear pin failure and inadequate maintenance procedures leading to a structural failure of the towbar.Pre-existing shear pin failure and inadequate maintenance procedures leading to a structural failure of the towbar.

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