Narrative:

Airline incorrectly loaded the inspection/overhaul requirements for the 10;666 flight cycle inspection/overhaul of the inboard flap actuators which is a task as outlined in the bombardier maintenance requirement manual (mrm). Need I remind you the flap actuators on a CL600-2b19 are restricted under a current ad; so the ad was also violated. Some of these actuators had as many as 3;000 cycles past the maximum of 10;666. In all I estimate 6-8 aircraft and as many as 25 actuators. The records are unclear in that regard. Airline did; once the error was discovered; replace the said actuators with repaired/overhauled units but this is only a small portion of oversight I have seen in all the airline fleet types. Airline is having severe monetary issues and cannot currently afford to properly maintain its fleets to standard. I'm afraid this is only the tip of the iceberg as so many personnel have quit the company; leaving an overwhelming amount of work for the few who have remained. Airline continues to attempt to cut costs by utilizing the same people for multiple roles; mainly in upper mgt. Floor personnel are replaced with lower paid entry level persons without adequate experience; even the majority of our training department has left with no replacements. I fear for my fellow co-workers as well as the general public and that is the reason for this report.callback conversation with reporter revealed the following information: reporter stated the airworthiness directive (ad) for the crj-200 flap system has been amended many times since the first issue in 1999; most recently in february 2008. The flaps are electronically controlled and mechanically operated. The actuator internal seals are allowing internal actuator fluid to bypass the seals and then freeze; locking up the individual actuator.

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Original NASA ASRS Text

Title: LEAD MECHANIC RPTS HIS CARRIER INCORRECTLY LOADED THE INSPECTION/OVERHAUL REQUIREMENTS FOR THE INBOARD FLAP ACTUATORS AT 10;666 FLT CYCLES. SOME ACTUATORS WERE 3;000 CYCLES PAST THE MAXIMUM 10;666 PER AD NOTE.

Narrative: AIRLINE INCORRECTLY LOADED THE INSPECTION/OVERHAUL REQUIREMENTS FOR THE 10;666 FLT CYCLE INSPECTION/OVERHAUL OF THE INBOARD FLAP ACTUATORS WHICH IS A TASK AS OUTLINED IN THE BOMBARDIER MAINT REQUIREMENT MANUAL (MRM). NEED I REMIND YOU THE FLAP ACTUATORS ON A CL600-2B19 ARE RESTRICTED UNDER A CURRENT AD; SO THE AD WAS ALSO VIOLATED. SOME OF THESE ACTUATORS HAD AS MANY AS 3;000 CYCLES PAST THE MAXIMUM OF 10;666. IN ALL I ESTIMATE 6-8 ACFT AND AS MANY AS 25 ACTUATORS. THE RECORDS ARE UNCLEAR IN THAT REGARD. AIRLINE DID; ONCE THE ERROR WAS DISCOVERED; REPLACE THE SAID ACTUATORS WITH REPAIRED/OVERHAULED UNITS BUT THIS IS ONLY A SMALL PORTION OF OVERSIGHT I HAVE SEEN IN ALL THE AIRLINE FLEET TYPES. AIRLINE IS HAVING SEVERE MONETARY ISSUES AND CANNOT CURRENTLY AFFORD TO PROPERLY MAINTAIN ITS FLEETS TO STANDARD. I'M AFRAID THIS IS ONLY THE TIP OF THE ICEBERG AS SO MANY PERSONNEL HAVE QUIT THE COMPANY; LEAVING AN OVERWHELMING AMOUNT OF WORK FOR THE FEW WHO HAVE REMAINED. AIRLINE CONTINUES TO ATTEMPT TO CUT COSTS BY UTILIZING THE SAME PEOPLE FOR MULTIPLE ROLES; MAINLY IN UPPER MGT. FLOOR PERSONNEL ARE REPLACED WITH LOWER PAID ENTRY LEVEL PERSONS WITHOUT ADEQUATE EXPERIENCE; EVEN THE MAJORITY OF OUR TRAINING DEPT HAS LEFT WITH NO REPLACEMENTS. I FEAR FOR MY FELLOW CO-WORKERS AS WELL AS THE GENERAL PUBLIC AND THAT IS THE REASON FOR THIS REPORT.CALLBACK CONVERSATION WITH RPTR REVEALED THE FOLLOWING INFO: RPTR STATED THE AIRWORTHINESS DIRECTIVE (AD) FOR THE CRJ-200 FLAP SYSTEM HAS BEEN AMENDED MANY TIMES SINCE THE FIRST ISSUE IN 1999; MOST RECENTLY IN FEBRUARY 2008. THE FLAPS ARE ELECTRONICALLY CONTROLLED AND MECHANICALLY OPERATED. THE ACTUATOR INTERNAL SEALS ARE ALLOWING INTERNAL ACTUATOR FLUID TO BYPASS THE SEALS AND THEN FREEZE; LOCKING UP THE INDIVIDUAL ACTUATOR.

Data retrieved from NASA's ASRS site as of May 2009 and automatically converted to unabbreviated mixed upper/lowercase text. This report is for informational purposes with no guarantee of accuracy. See NASA's ASRS site for official report.