N111AX

Part: LANDING GEAR — MALFUNCTIONED · airframe 77,168 hrs · 65,299 cycles

GEAR DOWN UNCOMMANDED WITH HANDLE IN UP POSITION. NO RED LIGHTS IN HANDLE. 3 GREEN INDICATORS.

Part: SQUAT SWITCH — INTERMITTENT (LANDING GEAR) · airframe 75,580 hrs · 64,150 cycles

PILOT REPORTED CABIN PRESSURIZATION DUMPED AT 10,500 FEET, O2 MASKS WERE DEPLOYED AND AIRCRAFT LANDED WITHOUT INCIDENT. MAINTENANCE PERFORMED TROUBLESHOOTING AND FOUND THAT THE LANDING GEAR SQUAT SWITCH WAS INTERMITTENT AND CAUSING FALSE READINGS.

Part: CONTROLLER — MALFUNCTIONED (CABIN PRESSURE) · airframe 75,577 hrs · 64,146 cycles

PILOT REPORTED HE EXPERIENCED RAPID DECOMPRESSION AT 17,600 FEET. DEPLOYED O2 MASKS AND RETURNED TO ANCHORAGE AND LANDED WITHOUT ANY INCIDENTS OR PROBLEMS. MAINTENANCE PERFORMED TROUBLESHOOTING, REPLACED PRESSURIZATION CONTROLLER, PERFORMED PRESSURE CHECKS ON GROUND WITHOUT ANY FAILURES.

Part: DOUBLER — CORRODED (FUSELAGE) · airframe 74,387 hrs · 63,278 cycles

DOUBLER FOUND CRACKED AT NUT-PLATE DURING DETAILED FUSELAGE CAMP INSPECTION. REMOVAL OF DOUBLER FOR REPAIR/REPLACEMENT DISCLOSED ADDITIONAL CORROSION DAMAGE TO THE DOUBLER. REPLACEMENT OF DOUBLER REQUIRED.

Part: LENS — DETACHED (LT WING TIP) · airframe 73,916 hrs · 62,930 cycles

LEFT WING TIP NAV STROBE LENS COVER LOST INFLIGHT.

Part: ACTUATOR — FAILED (MLG) · airframe 73,091 hrs · 62,351 cycles

PILOT REPORTED THAT THE LANDING GEAR FAILED TO FULLY RETRACT, AIRCRAFT RETURNED TO HOME STATION. MAINTENANCE REMOVED AND REPLACED RIGHT MAIN LANDING GEAR ACTUATOR, OPERATIONAL CHECK SUCCESSFUL.

Part: ACTUATOR — CRACKED (NLG) · airframe 73,060 hrs · 62,329 cycles

WHILE PERFORMING HEAVY MAINTENANCE INSPECTION AND SCHEDULED X-RAY OF NLG ACTUATOR CAP, TEST RESULTS SHOWED NOSE LANDING GEAR ACTUATOR CAP TO BE CRACKED. MAINTENANCE REMOVED AND REPLACED NOSE LANDING GEAR ACTUATOR WITH SERVICEABLE.

Part: DOOR FRAME — CRACKED (AIRSTAIR) · airframe 72,761 hrs · 62,124 cycles

DURING MAINTENANCE VISUAL INSPECTION OF AIRSTAIR DOOR, FOUND A CRACK ON AIRSTAIR DOOR FRAME TO BE OUT OF LIMITS IAW SRM 53-90-08. AIRSTAIR DOOR FRAME WAS REPLACED.

Part: SENSOR — FAILED (TEMP) · airframe 39,131 hrs · 42,178 cycles

PILOT REPORTED THE LEFT ENVIRONMENTAL FAIL DURING CLIMB OUT, PILOT CYCLED ENVIROMENTAL SYS OFF THEN OPEN AND RECEIVED THE RIGHT ENVIROMENTAL FAIL LIGHT. MAINTENANCE REMOVED AND REPLACED CENTER TEMPATURE SENSOR AND OPERATIONAL CHECKS WERE SUCCESSFUL.

Part: FCU — UNRESPONSIVE (LT ENGINE) · airframe 71,786 hrs · 61,375 cycles

PILOT REPORTED THAT THE LEFT HAND ENGINE WAS UNRESPONSIVE TO POWER LEVER INPUT AND WOULD NOT COME OUT OF IDLE. MAINTENANCE PERSONAL REMOVED AND REPLACED THE LEFT HAND ENGINE FUEL CONTROL UNIT, PERFORMED RIGGING, OPERATIONAL AND LEAK CHECKS OF THE LEFT HAND ENGINE, ALL SUCCESSFUL. AIRCRAFT WAS RETURNED TO SERVICE.

Part: FRAME — CRACKED (FUSELAGE) · airframe 71,399 hrs · 61,055 cycles

WHILE AIRCRAFT WAS IN SCHEDULED HEAVY MAINTENANCE, MECHANIC WAS PERFORMING VISUAL C-CHECK AND FOUND A CRACK IN FRAME AT FS 509.50, WL 96 APPROXIMATELY (JUST AFT OF CARGO DOOR). P/N:114-430125-5

Part: FRAME — CRACKED (FUSELAGE) · airframe 71,399 hrs · 61,055 cycles

WHILE AIRCRAFT WAS IN SCHEDULED HEAVY MAINTENANCE, MECHANIC WAS PERFORMING VISUAL C-CHECK AND FOUND A CRACK IN FRAME P/N:114-430121-33 AT FS 456.00 APPROXIMATELY WL 96(JUST FORWARD OF CARGO DOOR).

Part: CIRCUIT BREAKER — BURNED (COCKPIT) · airframe 69,821 hrs · 59,805 cycles

CIRCUIT BREAKER PANEL STARTED SMOKING AFTER LANDING. FLIGHT CREW SHUTDOWN ACFT AND EVACUATED SAFELY. MAINTENANCE LOCATED AND REPLACED OVERHEATED 5 AMP CIRCUIT BREAKER FOR ENGINE INSTRUMENT LIGHTING.

Part: CABLE — BROKEN (AIRSTAIR DOOR) · airframe 67,158 hrs · 57,569 cycles

ATTEMPTING TO DEPLANE, AIR STAIR DOOR WOULD NOT OPEN. FOUND ONE DOOR CAM OPERATING CABLE HAD BROKEN.

Part: LIGHT — INTERMITTENT (COCKPIT) · airframe 66,989 hrs · 57,418 cycles

NOSE GEAR GREEN LIGHTS INTERMITTENT ON LANDING, NO OTHER WARNING INDICATION. DECLARED AN EMER FOR PRECAUTION. ACFT LANDED WITHOUT INCIDENT. CAUSE OF INTERMITTENT GREEN LIGHT NOT YET DETERMINED.

Part: HANDLE — MISSING (CARGO DOOR) · airframe 66,050 hrs · 56,016 cycles

PILOT REPORTED CARGO DOOR EXTERIOR HANDLE MISSING AFTER LANDING.

Part: PLUNGER — OUT OF ADJUST (CARGO DOOR) · airframe 62,933 hrs · 53,842 cycles

WHEN THE ACFT REACHED ALTITUDE OF 22,000 FT. THE AFT CARGO DOOR WARNING LIGHT CAME ON. WHEN ACFT DROPPED IN ALTITUDE BELOW 20,000 FT. THE CARGO DOOR WARNING LIGHT EXTINGUISHED. FLIGHT CREW RETURNED TO DEPARTURE AND CALL MX. MX HAD FLIGHT CREW INSPECT CARGO DOOR FOR ANY DEFECTS, NONE WERE NOTED. CARGO DOOR WARNING LIGHT WAS DEFERRED IAW GMM PROCEDURES. MEL 52-2 WAS APPLIED. ON THE RETURN FLIGHT NO DEFECTS WERE NOTED IN OPERATION OF THE CARGO DOOR WARNING LIGHT SYS. CARGO DOOR WAS INSPECTED IN MX AND NO DEFECTS NOTED. CARGO DOOR WARNING LIGHT WAS PLACED ON DEFERRAL FOR FURTHER MONITORING. THE CONTINUED FLIGHT DAY NO DEFECTS WERE NOTED IN THE CARGO DOOR WARNING LIGHT SYSTEM. MEL WAS CLEARED BY ADJUSTING BAYONET SAFETY SWITCH PLUNGER, CLEANING AND LUBING OTHER SWITCHES CHECKED RIGGING IAW MM 52-70-00. ACFT OK FOR SERVICE.

Part: SOCKET — UNSECURE (MLG INDICATOR) · airframe 59,328 hrs · 50,491 cycles

ON APPROACH WITH THE LANDING GEAR SELECTED DOWN, THE RT MAIN GEAR DID NOT INDICATE DOWN AND LOCKED. THE PILOT CYCLED THE GEAR AGAIN AND STILL DID NOT GET A RT MAIN GEAR DOWN AND LOCKED INDICATION. THE LANDING WAS ABORTED. THE PILOT TAPPED ON THE LIGHT AND IT CAME ON. THE AIRPLANE WAS LANDED AND BROUGHT INTO THE HANGAR FOR INVESTIGATION. IT WAS DISCOVERED THAT THE LANDING GEAR INDICATOR LIGHTS SOCKET WAS NOT LATCHED. THE SOCKET WAS LATCHED AND CHECKED FOR SECURITY. THE GEAR WAS CYCLED TWICE SUCCESSFULLY AND THE AIRPLANE WAS RELEASED FOR FLIGHT. AT THIS TIME IT IS SUSPECTED THAT THE SOCKET WAS NOT RESET CORRECTLY AFTER A BULB CHANGE OR MAY HAVE BEEN INADVERTANTLY UNLATCHED BY SOMEONE PUNCHING BUTTONS.

Part: EXHAUST STACK — CRACKED (LT ENGINE) · airframe 53,853 hrs · 45,448 cycles

PILOT REPORTED OCCASIONAL EXHAUST FUMES IN CABIN. CONFIRMED THAT THE CREW SMELLED EXHAUST ON ROLLOUT WITH PROPS IN BETA AND HAD SMELLED IT AT AN ENGINE START (AS IS COMMON WHEN STARTING WITH A TAIL WIND). MX LOCATED A CRACKED HEATED INTAKE LIP STUB PIPE ON THE LT ENG INBD EXHAUST STACK AND REPLACED THE STACK.

Part: CABLE — SEPARATED (ELEVATOR TRIM) · airframe 52,996 hrs

PILOT REPORTED THAT PITCH TRIM SEEMED TO SLIP - RETURNED TO AIRPORT. MAINTENANCE REPLACED A BROKEN ELEVATOR TRIM CABLE.

Part: WINDSHIELD — CRACKED (ZONE 200) · airframe 51,106 hrs · 42,877 cycles

LT WINDSHIELD BROKE IN CRUISE - RED GLOW FROM HEATER ELEMENTS UNTIL WINDSHIELD HEAT TURNED OFF. UNEVENTFUL LANDING MADE AT ORIGINAL DESTINATION. MX REPLACED THE LT WINDSHIELD DUE TO OUTER PANE FAILURE.

Part: SKIN — CORRODED (BS 363-378) · airframe 51,016 hrs · 42,799 cycles

DURING INSP, THE MECHANIC NOTICED THE BELLY BEACON FRONT FASTENER WAS LOOSE. UPON INSP, THE MECHANIC DETERMINED THAT THERE WAS CORROSION UNDER THE BEACON MOUNT. THE BELLY SKIN REQUIRED A PATCH REPAIR TO REMOVE THE DAMAGED AREA.

Part: NIPPLE — CRACKED (ENGINE OIL) · airframe 49,584 hrs · 41,505 cycles

PILOT REPORTED LOSS OF OIL PRESSURE, NR1 ENGINE. ENGINE SECURED IN FLIGHT AND AC RETURNED TO DEPARTURE AIRPORT AND MADE AN UNEVENTFUL LANDING. MAINT REPLACED THE NR1 ENGINE TORQUE PRESSURE LINE DUE CRACKED NIPPLE IN HOSE END. INSPECTION OF CRACKED HOSE NIPPLE DID NOT INDICATE CAUSE OF FAILURE. DESTRUCTIVE TESTING (INTENSE OVER TORQUE) OF OTHER END OF SAME HOSE DID NOT RESULT IN SIMILAR CRACKING FAILURE. DESTRUCTIVE TESTING OF SECOND SAMPLE OF SAME PN. NIPPLE DID NOT RESULT IN SIMILAR CRACKING FAILURE. SUSPECT DEFECTIVE MATERIAL / PROCESSING OF HOSE NIPPLE AT MFG OR ORIGINAL ASSY. HOSE ASSY DATE A1Q08 AND 3Q07 ON WO NR 108987.

Part: TUBE — LEAKING (TIRE) · airframe 48,639 hrs

PILOT REPORTED NOSE TIRE FLAT ON LANDING. REPLACED TIRE ASSEMBLY DUE FAILED INNER TUBE. WE ARE EXPERIENCING MULTIPLE FAILURES, BURST TUBES FROM THIS MFG. MFG PREVIOUSLY NOTIFIED.

Part: TUBE — BLOWN (NLG TIRE) · airframe 48,633 hrs

PILOT REPORTED NOSE TIRE FLAT ON LANDING. REPLACED TIRE ASSY DUE FAILED INNER TUBE. WE ARE EXPERIENCING MULTIPLE FAILURES / BURST TUBES FROM THIS MFG. MFG PREVIOUSLY NOTIFIED.

Part: TUBE — FAILED (NLG TIRE) · airframe 48,537 hrs · 40,668 cycles

PILOT STOPPED AIRCRAFT ON TAXIWAY DUE NOSE TIE VIBRATION. REPLACED FLAT NOSE TIRE. TEARDOWN INSPECTION OF TIRE INDICATED A BURST TUBE AT A INSTALLATION FOLD. INSPECTION OF TUBE MATERIAL AT BURST AREA APPEARED TO RESEMBLE A CRACK MORE THAN A TEAR. THIS IS THIS WAS THE LATEST OF A STRING OF FLAT TIRES FOR UNDETERMINED REASONS.

Part: WIRE — SHORTED (ELECTRICAL) · airframe 46,895 hrs · 39,358 cycles

PILOT REPORTED (CAN NOT TURN ON BATTERY POWER), LOCATED BLOWN 60 AMP. CURRENT LIMITER CAUSED BY SHORT TO GROUND ON NR 6 GAUGE WIRE (WIRE NR P30A6) AT BLEED AIR DUCT PN. 114-550159-1. REPAIRED WIRE AND DUCT (HOLE IN DUCT), REMOVED 1 FOOT OF EXCESS LENGTH OF WIRE AND INSTALLED WIRE BUNDLE CLAMP STANDOFF AT RT WING LEADING EDGE BRACKET PN 114-120069-1 TO CORRECT LOW CLEARANCE PROBLEM.

Part: WINDSHIELD — CRACKED (COCKPIT) · airframe 45,705 hrs · 38,411 cycles

PILOT REPORTED LT WINDSHIELD CRACKED AT 400 FT ON DEPARTURE. PILOT BURNED OFF FUEL AND RETURNED TO DEPARTURE FOR WINDSHIELD REPLACEMENT.

Part: PULLEY — FROZEN (CONTROL CABLE)

PILOT REPORTED, THOUGHT THAT THE RUDDER HAD EXPERIENCED A -FREEZING- CONDITION WHILE IN FLIGHT (PROBLEM HAD RESOLVED ITSELF PRIOR TO LANDING). MAINTENANCE INSPECTED A KNOWN PROBLEM AREA UNDER THE CARGO FLOOR INSIDE THE CARGO DOOR (FS 505 WL 88) AT THE RUDDER CABLE PULLEY BRACKET. MAINTENANCE FOUND EVIDENCE THAT ICE HAD ACCUMULATED IN THE AREA BETWEEN THE FUSELAGE SKIN AND RUDDER PULLEYS AND HAD LIKELY RESTRICTED MOVEMENT OF CABLES AND PULLEYS. VERIFIED THAT ADDITIONAL BELLY DRAINS HAD ALREADY BEEN INSTALLED IN THE AREA TO ALLEVIATE THIS KNOWN PROBLEM. RECENT RAMP LOADING IN HEAVY RAIN LIKELY EXCEEDED THE ABILITY DRAINS TO EXPEL THE LARGE VOLUME OF WATER INDUCED DURING LOADING AND THE WATER FROZE WHEN THE AI

Part: STRINGER — CORRODED (BS 210) · airframe 43,069 hrs

FOUND CORROSION ON STRINGER 15 LH AT FUSELAGE STATION 210. THE REPAIR REQUIRED DER. ENGINEERING ASSISTANCE DUE NO OEM DOCUMENT COVERING THE REQUIRED REPAIR.

Part: SMOKE — DETECTED (COCKPIT) · airframe 42,044 hrs · 35,411 cycles

ODOR OF SMOKE IN COCKPIT - SHUT OFF BLEED AIR AND EVIRONMENTAL AIR, ODOR WENT AWAY - MAINTENANCE COULD NOT LOCATE ANY SOURCE OF THE ODOR - OPS CHECK FLIGHT SCHEDULED.

Part: WINDSHIELD — CRACKED (COCKPIT) · airframe 41,652 hrs · 35,105 cycles

PILOT REPORTED LT WINDSHIELD CRACKED OUTER PLY VERIFIED CRACKED - REPLACED WINDSHIELD (WITHIN MFG. WARRANTY PERIOD).

Part: SAFETY SWITCH — INTERMITTENT (RT MLG) · airframe 41,571 hrs · 35,051 cycles

PIREP - LANDING GEAR WOULD NOT RETRACT. MAINTENANCE REPLACED INTERMITTENT RT LANDING GEAR SAFETY SWITCH.

Part: EXHAUST DUCT — DISCONNECTED (NR 1 ENGINE) · airframe 38,029 hrs · 32,183 cycles

PILOT REPORTED EXHAUST SMELL IN CABIN ON TAKEOFF AND CLIMB. MAINTENANCE LOCATED A DISCONNECTED NR 1 ENGINE INTAKE HEATED LIP (EXHAUST DUCT) TUBE. EXHAUST COULD HAVE BEEN INGESTED BY THE ENGINE AND THEN MIXED WITH THE BLEED AIR. NO PART FAILURE WAS OBSERVED.

Part: SWITCH — WORN (LT MLG) · airframe 36,171 hrs · 30,649 cycles

PILOT REPORTED HAVING TO CYCLE THE LANDING GEAR TO GET THE LEFT MAIN TO INDICATE DOWN AND LOCKED (GREEN) - MAINTENANCE REPLACED THE LEFT MAIN GEAR DOWN AND LOCK SWITCH.

Part: PUMP — FAILED (FUEL SYS)

IN CRUISE FLIGHT, RT ENGINE LOW FUEL PRESSURE ANNUNCIATOR CAME ON AND THE ENGINE SHUT DOWN (FLAMEOUT)-THE AIRCRAFT MADE AN UNEVENTFUL LANDING AT AN ALTERNATE AIRPORT. POST LANDING VISUAL INSPECTION AND GROUND RUNS DID NOT IDENTIFY ANY ABNORMALITIES. ENGINE AND AIRFRAME FUEL FILTERS WERE CLEANED OR REPLACED AND THE AIRCRAFT WAS FERRIED BACK TOT HE MAINTENANCE BASE (80 MINUTES) WITHOUT ANY OBSERVED FAULTS. MAINT REPLACED THE LOW PSI FUEL PUMP AS A PRECAUTION. THE AIRCRAFT WAS PLACED IN A HANGAR TO THAW AND THE FUEL SUMPS WERE DRAINED OF SEDIMENT (SMALL AMOUNT OF WATER WAS REMOVED).

Part: YOKE — CRACKED (AILERON)

WHILE PERFORMING A SCHEDULED AILERON YOKE INSPECTION, FOUND THE RT AND LT AILERON YOKES CRACKED ON TWO SIDES (TOP AND BOTTOM) OF THE TAPER PIN HOLES, ALONG THE GRAIN OF THE METAL. THE CAUSE OF THE FAILURES WAS NOT EVIDENT.(K)

Part: CONTROL CABLE — FROZEN (RUDDER)

PILOT REPORTED RUDDER FROZEN IN FLIGHT, UNEVENTFUL LANDING MADE. PILOT REPORTED THE RUDDER BROKE FREE WHILE TAXING REMOVED CARGO COMPARTMENT FLOOR AT CARGO DOOR AND OBSERVED WATER FROZEN AROUND RUDDER CABLE PULLEYS AT FUSELAGE STATION 495. REMOVED WATER AFTER THAWING. ADDITIONAL PRESSURE DRAINS WERE INSTALLED. THIS IS THE THIRD INCIDENT OF THIS NATURE ON THIS AIRCRAFT TYPE THAT WE HAVE EXPERIENCED. (K)