N1563C

Part: SHAFT — SHEARED (AIRSTAIR HANDLE)

AFTER LANDING, THE FLIGHT CREW WAS UNABLE TO OPEN THE FORWARD AIRSTAIR DOOR USING THE INTERIOR HANDLE. THE PILOT WROTE UP THE AIRSTAIR DOOR HANDLE AS INOPERATIVE. MAINTENANCE REPLACED THE INTERIOR DOOR HANDLE ASSEMBLY AFTER FINDING THE SQUARE HANDLE SHAFT SHEARED EVEN WITH THE BASE OF THE HANDLE. THIS IS THE FIFTH FAILURE OF THIS PN ASSEMBLY IN OUR FLEET IN THE LAST YEAR.

Part: ENGINE — FAILED (NR 2)

ON DESCENT, NR 2 ENGINE TORQUE BEGAN TO FALL AND THE NR 2 ENGINE OIL PRESSURE WARNING LIGHT CAME ON. THE ENGINE WAS SECURED. THE ODOR OF OIL SMOKE WAS IN THE CABIN. THE AIRCRAFT LANDED WITHOUT INCIDENT. MAINTENANCE VERIFIED A LACK OF ENGINE OIL ON THE DIP STICK (6 QUARTS LOW), METAL IN THE ENGINE OIL SCREEN, OIL RUNNING OUT OF THE ENGINE INTAKE AND UNUSUAL NOISE WHEN TURNING THE PROPELLER. THE ENGINE IS TO BE REPLACED.

Part: PUMP — LEAKING (DRAIN)

A FAILED NR 2 ENGINE LOW PRESSURE FUEL BOOST PUMP WAS IDENTIFIED WHILE THE AIRCRAFT WAS IN THE HANGAR FOR OTHER MAINTENANCE. THE FAILURE WAS IDENTIFIED BY FUEL DRIPPING OUT OF THE NR 2 ENGINE GANG DRAIN DUE TO PREVIOUS COMPLIANCE WITH MFG MANDATORY SB 71-3307. THIS IS THE SECOND OCCURRENCE OF FUEL RESIDUE BEING FOUND IN THE LANDING GEAR WELL AND ON THE LANDING GEAR DUE TO THE POST SB LOCATION OF THE LOW PRESSURE FUEL PUMP DRAIN. SUGGEST SB 71-3307 BE REVIEWED AND A POSSIBLE CHANGE TO DRAIN POINT LOCATION BE INVESTIGATED. CONSIDER A CHANGE OF THE DRAIN CONNECTION TO THE ENGINE BREATHER LINE TO BE A SAFER LOCATION FOR THE VENTING OF RAW FUEL.

Part: FIRE LOOP — FALSE INDICATION (NR 1 ENG EXHAUST)

FLIGHT CREW RETURNED TO RAMP AFTER INDICATION OF FIRE IN THE NR 1 ENGINE. MAINTENANCE VERIFIED THAT THE WARNING WAS FALSE AND WAS CAUSED BY CONTACT BETWEEN THE FORWARD FIRE DETECT LOOP AND A DISCONNECTED O/B HEATED INTAKE LIP FLEX TUBE. MAINTENANCE REPLACED THE FORWARD FIRE DETECT LOOP AND RECONNECTED THE FLEX DUCT.

Part: SPAR CAP — CORRODED (CENTER SECTION)

FOUND CORROSION ON FORWARD SIDE OF MAIN WING SPAR LOWER CAP BOND ASSY. THE AFFECTED AREA IS UNDER THE CABIN FLOOR. CORROSION WAS FOUND ON THE FORWARD FACE OF THE SPAR CAP AND WAS DISTRIBUTED ACROSS THE SPAR CAP. RECOMMEND THAT IMPROVED PAINT BE APPLIED TO THE SPAR CAP AND WATER/SEDIMENT DRAINS BE INSTALLED JUST FORWARD OF THE SPAR CAP, NONE ARE INSTALLED AT THIS TIME.

Part: WINDSHIELD — CRACKED (COCKPIT)

COPILOTS WINDSHIELD OUTER PANE CRACKED AFTER TAKEOFF. AIRCRAFT RETURNED TO AIRPORT WITHOUT INCIDENT.

Part: SWITCH — DISCONNECTED (LT ENGINE)

WHILE PERFORMING OTHER MAINTENANCE, FOUND LEFT ENGINE SQUIB POWER SWITCH DISLOCATED FROM ENGINE FIRE EXTINGUISHER ANNUNCIATOR/ACTUATOR ASSEMBLY. FOUND SQUIB SWITCH MODULE NOT PROPERLY RETAINED BY TABS ON ANNUNCIATOR BODY. THIS CONDITION HAS BEEN FOUND ON HALF OF INSPECTED AIRCRAFT. SUGGEST A CHANGE IN DESIGN OF THE ASSEMBLY FOR POSITIVE ATTACHMENT OF SQUIB POWER SWITCH. NOTE: THE CONDITION FOUND ON THIS ASSEMBLY WOULD PREVENT THE FLIGHT CREW FROM BEING ABLE TO DISCHARGE THE AFFECTED ENGINE FIRE BOTTLE AT ANYTIME. ALSO, THERE IS NO WAY FOR THE CREW TO PREFLIGHT THIS SYSTEM TO VERIFY THAT THE FIRE BOTTLE SQUIB COULD IN FACT BE BLOWN IF NEEDED.

Part: SWITCH — DISCONNECTED (FIRE EXTING)

WHILE PERFORMING OTHER MAINTENANCE, FOUND LT ENGINE SQUIB POWER SWITCH DISLOCATED FROM ENGINE FIRE EXTINGUISHER ANNUNCIATOR/ACTUATOR ASSEMBLY. FOUND SQUIB SWITCH MODULE NOT PROPERLY RETAINED BY TABS ON ANNUNCIATOR BODY. THIS CONDITION HAS BEEN FOUND ON HALF OF INSPECTED AIRCRAFT. SUGGEST A CHANGE IN DESIGN OF THE ASSEMBLY FOR POSITIVE ATTACHMENT OF SQUIB POWER SWITCH. NOTE: THE CONDITION FOUND ON THIS ASSY WOULD PREVENT THE FLIGHT CREW FROM BEING ABLE TO DISCHARGE THE AFFECTED ENGINE FIRE BOTTLE AT ANYTIME. ALSO, THERE IS NO WAY FOR THE CREW TO PRE-FLIGHT THIS SYSTEM TO VERIIFY THAT THE FIRE BOTTLE SQUIB COULD BE BLOWN IF NEEDED.

Part: SWITCH CAM — LOOSE (MLG)

AFTER DEPARTURE, GEAR SELECTED UP AND NOSE GEAR RETRACTED BUT MAINS DID NOT. GEAR SELECTED DOWN AND GEAR SHOWED DOWN AND LOCKED. GEAR SELECTED UP AGAIN AND GEAR WOULD NOT RETRACT. GEAR SELECTED DOWN AND INDICATED THREE GREEN. AIRCRAFT RETURNED TO AIRPORT AND MADE AN UNEVENTFUL LANDING. AIRCRAFT THEN FLOWN TO ANCHORAGE WITH GEAR DOWN. (M)

Part: OIL COOLER — CRACKED (OIL SYSTEM)

AFTER DEPARTURE FROM FAI, PILOT NOTICED LOW OIL PRESSURE LIGHT ON LEFT ENGINE FLICKER, OBSERVED OIL PRESSUR GAUGE DROPPING SLOWLY AND PERFORMED A PRECAUTIONARY SHUT DOWN ON THAT ENGINE. OIL PRESSURE WAS AT 65 PSI AT THE TIME OF SHUTDOWN. AIRCRAFT RETURNED FOR AN UNEVENTFUL LANDING. FOUND OIL LEAKING FROM LEFT NACELLE BELOW THE OIL COOLER. MAINTENANCE REPLACED THE OIL COOLER AND GROUND LEAK CHECKED OK. REMOVED OIL COOLER VERIFIED CRACKED AT SIDE WELD SEAM. (M)

Part: SPAR — CORRODED (WING)

FOUND CORROSION ON FORWARD SIDE OF MAIN WING SPAR LOWER CAP BOND ASSY. THE AFFECTED AREA IS UNDER THE CABIN FLOOR IN THE CABIN. CORROSION WAS FOUND ON THE FORWARD FACE OF THE SPAR CAP AND WAS DISTRIBUTED IN SMALL AREAS ACROSS THE SPAR, JUST ABOVE THE EDGE OF THE SEALANT THAT IS USED TO SEAL THE SPAR RIVET FLANGE. DAMAGE WAS DETERMINED TO BE NEGLIGIBLE AFTER CORROSION REMOVAL.

Part: COMPRESSOR — FOD DAMAGE (ENGINE INTERNAL)

DURING DESCENT FROM FL250 TO FL230 PILOT NOTICED NR 2 ENG ITT AT 760 DEGREES CELSIUS. PILOT REDUCED POWER TO 720 DEGREES ITT. ONCE LEVEL AT FL 230, NR 2 ENGINE STARTED TO SURGE WITH SIGNS OF COMPRESSOR STALL. PILOT REDUCED POWER ON NR 2 TO LESS THAN 800 LBS OF TORQUE. DURING THE FIRST ATTEMPTING TO INCREASE TORQUE, AT 800 LBS ENGINE STARTED TO STALL AGAIN. PILOT TURNED AROUND AND RETURNED TO BET. THE SECOND ATTEMPTS TO INCREASE POWER, PILOT BROUGHT POWER UP TO 1500 LBS WITH SOME PROBLEMS. PILOT SHUTDOWN AND SECURED NR 2 ENGINE. AIRCRAFT LANDED WITHOUT INCIDENT. MAINTENANCE FOUND FOD DAMAGE TO FIRST STAGE COMPRESSOR. (M)

Part: WIRE — CHAFED (CABIN)

WHEN LANDING GAR SELECTED DOWN, LANDING GEAR CONTROL CIRCUIT BREAKER TRIPPED AND WOULD NOT RESET. MAINTENANCE FOUND WIRE NR G15G CHAFFING AGAINST SIDEWALL STRUCTURE. REPAIRED DAMAGED WIRE. LANDING GEAR OPS CHECKED NORMAL, AIRCRAFT RELEASED FOR FLIGHT. WIRE G15G IS LOCATED IN A LARGE WIRE BUNDLE THAT RUNS UNDER THE MAIN CABIN FLOOR AND A LONG THE CABIN SIDEWALL, THEN OUT TO THE LEFT WING. THE DAMAGED WIRE HAD BEEN CHAFFING ON THE SIDEWALL STRUCTURE ABOUT TWO INCHES ABOVE CABIN FLOOR LEVEL. THERE WHERE SEVERAL OTHER WIRES IN THIS BUNDLE THAT WHERE FOUND TO BE DAMAGED. (M)

Part: DIODE — FAILED (LANDING GEAR)

WHEN PILOT SELECTED LANDING GEAR DOWN, LANDING GEAR CONTROL CIRCUIT BREAKER TRIPPED AND WOULD NOT RESET. PILOT MANUALLY EXTENDED THE LANDING GEAR. AIRCRAFT LANDED WITHOUT INCIDENT. MAINTENANCE REPLACED DAMAGED DIODE IN THE LANDING GEAR DOWN CIRCUIT, AT THE HYDRAULIC POWER PACK SOLENOID. PERFORMED SEVERAL GEAR RETRACTIONS AND TEST FLEW THE AIRCRAFT, LANDING GEAR OPERATED NORMALLY. (M)

Part: FUEL FILTER — CONTAMINATED (LEFT ENGINE)

APPROX 30 MINUTES OUT, INBOUND TO ANC, LEFT ENGINE FUEL FLOW, ITT, TORQUE AND N1 RPM DECREASED. PILOT ALSO REPORTED COMPRESSOR STALL. LEFT ENGINE SHUT DOWN. AIRCRAFT LANDED AT ANC WITHOUT INCIDENT. MAINTENANCE FOUND LEFT AIRFRAME FUEL FILTER CLOGGED WITH RUST AND OTHER DEBRIS. REPLACED AIRFRAME FUEL FILTER ELEMENTS AND ENGINE DRIVEN FUEL PUMP FILTER. AIRCRAFT GROUND RUN AND TEST FLOWN WITH NO PROBLEMS. AIRCRAFT RETURNED TO SERVICE. CONTINUING INVESTIGATION AS TO SOURCE OF FUEL CONTAMINATION. (M)