Investigation Summary
The flight was operating a multi-leg domestic route and was heavily loaded for the departure from Aurangabad. The runway at the time was 6,000 feet long, which provided a narrow margin for a Boeing 737-200 under high-temperature conditions. During the takeoff roll, Captain Singh initiated rotation significantly later than required. As the aircraft finally lifted off near the runway end, its left main landing gear and left engine struck a truck carrying cotton bales on the Beed road, which ran just 125 meters from the runway threshold. The impact severed the landing gear and damaged the left horizontal stabilizer and elevator. The crippled aircraft banked left, snapped three high-tension power lines, and struck two babool trees before slamming into the ground. The fuselage broke into two sections; the rear section inverted and was quickly consumed by fire, leading to the majority of the fatalities.
Final Conclusions
The Ministry of Civil Aviation concluded the primary causes were pilot error and regulatory failure. The captain used an incorrect rotation technique and initiated the maneuver too late for the aircraft's weight and environmental conditions. Additionally, the National Airports Authority (NAA) failed to regulate mobile traffic on the Beed road during flight operations. Previously, a gate had existed to stop traffic during takeoffs, but it had been removed years prior to the accident. Following the crash, the runway was extended by 3,000 feet and the traffic gates were reinstated.
Video Analysis
Indian Airlines 491 पहाड़ियों में टकराया Aurangabad | 1993 Pilot Error — A detailed look at the crash of Indian Airlines Flight 491, exploring the pilot's background, the short runway at Aurangabad, and the collision with a truck that led to the disaster.
If playback is blocked, the owner has disabled embedding — use the link above.
Airframe & Maintenance
Crew Experience
Captain
Had only 140 hours of experience as Pilot-in-Command.
First Officer
Systems & Failure Modes
Horizontal Stabilizer
A 98-inch portion of the left horizontal stabilizer detached after being struck by debris from the initial collision with the truck.
Thrust Reverser
The left engine's thrust reverser was severed during the impact, causing the engine to lose power and rotate at low RPM.
Elevator
A 115-inch section of the left elevator was damaged, severely compromising the pilots' ability to control the aircraft's pitch and roll.
Interesting Facts
- 01The aircraft was 18 years old and had accumulated 43,886 flight hours.
- 02The captain had only 140 hours of experience as a pilot-in-command on the Boeing 737.
- 03The truck involved was carrying cotton bales, which increased its height and contributed to the collision.
- 04A traffic gate that previously blocked the road during takeoffs had been removed in 1986.
- 05Official reports state 55 fatalities (53 passengers and 2 crew), though some secondary sources cite 56, likely due to a survivor succumbing to injuries later or manifest discrepancies.
Safety Actions & Advisories
Runway Extension
The runway at Aurangabad Airport was extended by 3,000 feet to provide a greater safety margin for jet aircraft.
Traffic Regulation
Authorities reinstated gates on the Beed road to ensure all mobile traffic is halted during aircraft takeoffs and landings.
Licensing Revocation
Captain Singh's pilot-in-command license was revoked, and the First Officer's license was suspended following the inquiry.