N2611X

Part: CIRCUIT BREAKER — FAILED (ZONE 200)

PILOT REPORTED PLASTIC BURNING SMELL IN CABIN SMELLS FROM LEFT C/B PANEL. MAINTENANCE INSPECTED AND FOUND THE STROBE LIGHT SWITCH INOP. THE SWITCH WAS REPLACED WITH NO FURTHER DEFECTS NOTED.

Part: SWITCH — FAILED (DE-ICE SYSTEM) · airframe 37,227 hrs · 43,092 cycles

PILOT REPORTED STRONG BURNING SMELL IN COCKPIT. NOTICED PROP DE-ICE GAUGE WAS ON BUT THE SWITCH WAS OFF. CYCLED SWITCH BREAKER. DE-ICE GAUGE TURNED OFF, BUT SWITCH REMAINED LOOSE. THEY PULLED C/B'S AS PRECAUTION. MAINTENANCE TROUBLESHOT TO BAD SWITCH. BYPASSED SWITCH AND PROP DEICE SYSTEM OPS CHECKS GOOD WITH NO SHORTS. THE SWITCH WAS REPLACED WITH NO FURTHER DEFECTS NOTED.

Part: NUT — EXCESS PLAY (ALTERNATOR) · airframe 36,928 hrs · 42,697 cycles

UPON REMOVAL OF AN ALTERNATOR FOR AN INTERNAL OIL LEAK, THE HUB NUT WAS FOUND TO BE LOOSE, ALLOWING THE THRUST WASHER TO ROTATE BY HAND. THE COTTER PIN REMAINED IN PLACE. THE UNIT WAS REMOVED FROM SERVICE PENDING FURTHER INVESTIGATION.

Part: BUSHING — MIGRATED (CONNECTING ROD) · airframe 34,095 hrs · 38,976 cycles

DURING ROUTINE INSPECTION AND REPLACEMENT OF THE RIGHT ENGINE CYLINDER #6 IT WAS DISCOVERED THAT THE CONNECTING ROD BUSHING OF THE #6 CYLINDER WAS FOUND TO BE LOOSE AND MIGRATING. THE CONNECTING ROD AND CYLINDER WILL BE REPLACED.

Part: HOSE — BROKEN (BRAKE SYSTEM) · airframe 33,972 hrs · 38,814 cycles

PILOT REPORTED RIGHT BRAKE FAILURE. MAINTENANCE INSPECTED AND FOUND THE FLEXIBLE HOSE CONNECTED TO THE RIGHT MASTER CYLINDER BROKEN. REMOVED AND REPLACED THE FLEXIBLE HOSE, AND PREFORMED BLAKE BLEEDING PROCEDURES. NO FURTHER DEFECTS NOTED.

Part: EXHAUST VALVE — DAMAGED (NR 2 CYLINDER) · airframe 20,272 hrs

CYLINDER REMOVED DUE TO LOW COMPRESSION AT INSPECTION; EXHAUST VALVE DISPLAYS EVIDENCE OF HEAT DAMAGE.

Part: CYLINDER — LOW PRESSURE (NR 5) · airframe 30,199 hrs

CYLINDER REMOVED DUE TO LOW COMPRESSION AT INSPECTION; EXHAUST VALVE DISPLAYS EVIDENCE OF HEAT DAMAGE.

Part: EXHAUST VALVE — DAMAGED (NR 4 CYLINDER) · airframe 30,138 hrs

CYLINDER REMOVED DUE TO LOW COMPRESSION AT INSPECTION. EXHAUST VALVE DISPLAYS EVIDENCE OF HEAT DAMAGE.

Part: EXHAUST VALVE — DAMAGED (NR 3 CYLINDER) · airframe 29,866 hrs

CYLINDER REMOVED DUE TO LOW COMPRESSION AT INSPECTION. EXHAUST VALVE DISPLAYS EVIDENCE OF HEAT DAMAGE.

Part: CALIPER — DEFECTIVE (LT BRAKE) · airframe 29,430 hrs · 32,071 cycles

PILOT REPORTED BRAKES FAILED ON PARKING. R & R THE LT BRAKE CALIPER & SERVICED BOTH LT & RT BRAKE SYSTEMS. OPERATIONAL & LEAK CHECKED GOOD.

Part: ALTERNATOR — INTERMITTENT · airframe 29,403 hrs · 32,003 cycles

PILOT REPORTED BOTH ALTERNATORS KEPT GOING OUT INFLIGHT. INSPECTED ALTERNATORS IAW MM CH 24. RAN ENGS & ALTERNATORS, ALL OPERATIONS CHECKED GOOD.

Part: DOOR — OPEN (LT WING) · airframe 29,048 hrs · 31,425 cycles

PILOT REPORTED THE LT WING LOCKER OPENED DURING FLIGHT. INSPECTED THE DOOR WITH NO DISCREPANCIES FOUND.

Part: LINE — FAULTY (LT ENGINE) · airframe 28,786 hrs · 31,032 cycles

PILOT REPORTED LT ENG NOT RESPONSIVE TO THROTTLE CHANGES, DEVELOPING AMBIENT PRESS. ENG SHUTDOWN IN FLIGHT. INSPECTED THE LT ENG & FOUND A BAD MANIFOLD PRESS, MAP, LINE. REPLACED LINE, RAN ENG & FOUND TO BE WITHIN OPERATING LIMITS IAW MM CHAPTER 72 & 81.

Part: SPAR — CRACKED (WING) · airframe 27,389 hrs · 29,142 cycles

DURING A SCHEDULED MX EVENT, TWO CRACKS WERE FOUND AT THE AFT CARRY THROUGH SPAR WEB FLANGES. THE CRACKS WERE APPROXIMATELY .75 INCHES IN LENGTH & WERE LOCATED AT FS 186.15, RBL 7.75 AT THE FWD & AFT SPAR FLANGE. THE DAMAGE WAS REPAIRED IAW ENGINEERING DRAWING PROVIDED FOR DAMAGE MAP.

Part: STARTER — LOOSE (LEFT ENGINE) · airframe 26,344 hrs · 27,947 cycles

DURING TAKEOFF, THE CREW REPORTED LT ENGINE DECREASING OIL PRESSURE. THE CREW ELECTED TO FEATHER THE PROP, SHUTDOWN THE ENGINE AND RETURN TO ORIGINAL BASE. CONTRACT MX PERFORMED AN INITIAL INSP AND DETERMINED THE LEFT STARTER HAD SEPARATED FROM THE STARTER ADAPTER CAUSING OIL LEAKAGE. HE REPORTED THE LEFT ENGINE WAS SHOWING 6 QTS OF OIL IN THE SUMP. THE OIL FILTER WAS INSPECTED ALONG WITH THE PROP GOVERNOR GASKET SCREEN WITH NO DEFECTS. THE LEFT STARTER AND STARTER ADAPTER WERE REPLACED AND THE ACFT WAS RETURNED TO SERVICE.

Part: WEB — CRACKED (ZONE 100) · airframe 26,250 hrs

DURING A ROUTINE SCHEDULED INSPECTION, A .62" CRACK WAS FOUND IN THE RT SIDE OF THE FORWARD SPAR WEB AT BS 154.50. DAMAGE WAS MAPPED AND SENT TO ENGINEERING. THE DAMAGED AREA WAS REPAIRED IAW A REPAIR DEFINITION SUPPLIED AND SUBSTANTIATED BY REPORT AAS-SSR-13-62, REV NC, DATED MAY 31, 2013.

Part: ENGINE — DAMAGED (RIGHT) · airframe 26,133 hrs

FLIGHT CREW REPORTED THAT DURING CRUISE, NOTICED DECREASING MANIFOLD PRESSURE AS WELL AS DIMINISHING OIL PRESSURE ON THE RT ENGINE AT 6,000". CREW SHUTDOWN ENGINE IN FLIGHT. LANDED SAFELY AT DESTINATION AIRPORT. ON MX INSPECTION, DISCOVERED CONNECTING RODS HAD PENETRATED THE CASE. OPEN

Part: DRAG BRACE — CRACKED (NLG) · airframe 26,432 hrs

AT SCHEDULED INSPECTION, NLG DRAG BRACE, PN 5142002-5 WAS FOUND TO BE CRACKED IN THE AREA OF NLG ACTUATOR ATTACH POINT. METHOD OF INSPECTION WAS DYE PENETRANT. THIS CRACK WAS FOUND TO BE BEYOND LIMIT ALLOWABLE OF MEB91-11R1. THIS UNIT HAS BEEN SCRAPPED & A REPLACEMENT DRAG BRACE HAS BEEN INSTALLED IN ACFT.

Part: BOLT — MISSING (TORQUE LINK) · airframe 25,602 hrs

PILOT REPORTED THAT DURING LANDING ROLLOUT, THE AIRPLANE YAWED TO THE RIGHT. THE PILOT WAS ABLE TO SAFELY TAXI THE ACFT OFF THE RUNWAY. UPON MX INSPECTION, IT WAS DISCOVERED THAT THE BOLT WAS MISSING FROM THE RT MLG TORQUE LINK AND THAT THE GEAR HAD SPUN 180 DEGREES. NO STRUCTURAL DAMAGE WAS DISCOVERED ON THE GEAR STRUT OR UPPER TRUNNION. TORQUE LINK BUSHING, BOLT, AND NUT WERE REPLACED.

Part: ALTERNATOR — FAILED (ZONE 600) · airframe 25,168 hrs

PILOT REPORTED AT APPLICATION OF TAKEOFF POWER, SMOKE BEGAN ENTERING THE COCKPIT FROM THE RT SIDE. TAKEOFF WAS ABORTED AND ACFT WAS SUBSEQUENTLY SHUTDOWN AND EVACUATED. ON INSPECTION BY MX, SEVERAL PANELS IN COCKPIT WERE INSPECTED AND FOUND NO EVIDENCE OF SMOKE OR FIRE. TURNED ON ALL SYSTEMS IN ACFT AND STILL NO EVIDENCE OR RECURRENCE OF SMOKE. RAN LT AND RT ENGINES, AND NOTED RIGHT ALTERNATOR OFF LINE, BUT NO SMOKE. INSPECTED RIGHT ALTERNATOR AND FOUND UNIT BURNED INTERNALLY. INSPECTED ALL ALTERNATOR WIRING FROM ENGINE TO COCKPIT WITH NO DAMAGE FOUND. R & R RT ALTERNATOR AND RT VOLTAGE REGULATOR.

Part: DRAG BRACE — CRACKED (NLG) · airframe 25,084 hrs

AT SCHEDULED INSPECTION, NLG DRAG BRACE, PN 5142002-5, WAS FOUND TO BE CRACKED IN THE AREA OF NLG ACTUATOR ATTACH POINT. METHOD OF INSPECTION WAS DYE PENETRANT. THIS CRACK WAS FOUND TO BE WITHIN ALLOWABLE LIMIT OF MEB91-11R1. THIS UNIT HAS BEEN REPAIRED IAW PROCEDURE OUTLINED IN MEB941-11R1 & RETURNED TO SERVICE.

Part: SWITCH — ARCED (HEATER) · airframe 24,387 hrs · 25,183 cycles

HEATER FAILED IN FLIGHT. ACFT DIVERTED, DUE TO ODOR OF ELECTRICAL BURNING AND SMALL AMOUNT OF SMOKE IN THE COCKPIT AREA. MX FOUND THE CYCLING SWITCH POINTS ON THE HEATER WERE ARCHING. R & R THE HEATER AND CYCLING POINTS TO CLEAR DISCREPANCY.

Part: DRAG BRACE — CRACKED (NLG) · airframe 23,103 hrs

AT SCHEDULED INSPECTION, NLG DRAG BRACE, OEM PN 5142002-5, WAS FOUND TO BE CRACKED IN THE AREA OF NLG ACTUATOR ATTACH POINT. METHOD OF INSPECTION WAS DYE PENETRANT. THIS CRACK WAS FOUND TO BE WITHIN ALLOWABLE LIMIT. THIS UNIT HAS BEEN REPAIRED IAW PROCEDURE OUTLINED IN MEB941-11R1 & RETURNED TO SERVICE.

Part: GYRO — ODOR (DIRECTIONAL) · airframe 21,797 hrs

IN CLIMB CONFIGURATION, (APPROX 1800 FT), CREW REPORTED HEADING FLAG IN VIEW. CLIMBING THROUGH 2000 FT, CREW REPORT STRONG SMELL "CHLORINE LIKE ODOR". CREW ELECTED TO RETURN TO BASE, AFTER CONCLUDING THAT THERE MAY BE AN ELECTRICAL SHORT CIRCUIT, OR POSSIBLE SMOKE IN THE COCKPIT/CABIN. CREW REDUCED ELECTRICAL LOAD, PERFORMED CABIN /FIRE /SMOKE CHECKLIST, AND LANDED UNEVENTFULLY. MX FOUND KG-102A REMOTE GYRO HAD SHORTED. R & R GYRO AND RETURNED ACFT TO SERVICE.

Part: STATIC INVERTER — BURNED (FORWARD FUSELAGE) · airframe 21,544 hrs

CREW REPORTED DURING CLIMB OUT, THE WIRING LOCATED ON THE LT SIDE OF THE HEATED (ELECTRIC) WINDSHIELD SPARKED, AND SMOKE IMMEDIATELY DEVELOPED. WINDSHIELD HEAT WAS TURNED OFF, AND THE SMOKE DISCONTINUED. ICE BEGAN TO DEVELOPE ON WINDSHIELD, RESULTING IN A TURN BACK TO BLOCK. MX FOUND ONE AVIONICS STATIC DISCHARGE SUPPRESSOR ASSY BURNED, THE HEATED WINDSHIELD SHORTED. REMOVED AND REPLACED HEATED WINDSHIELD AND BOTH STATICS SUPPRESSORS. AS A PRECAUTIONARY MEASURE, MX REPLACED THE WINDSHIELD STATIC INVERTER ALSO.

Part: SWITCH — OUT OF RIG (MLG) · airframe 21,340 hrs

CREW REPORTED, ON APPROACH, NORMAL GEAR DOWN INDICATION UNTIL FLAPS WERE SELECTED BEYOND 15 DEGREES. GEAR UNLOCK LIGHT ILLUMINATED, AND NOSE GEAR DOWN LOCK LIGHT FLICKERED, GEAR WARNING HORN SOUNDED. ABORTED APPROACH TO TROUBLESHOOT SYS. SUBSEQUENT GEAR EXTENSION RESULTED IN NORMAL INDICATION. AS A PRECAUTIONARY MEASURE, EMERGENCY GEAR EXTENSION WAS PREFORMED. LANDING WAS UNEVENTFUL. MX WAS ABLE TO DUPLICATE MALFUNCTION DURING GEAR SWING. RERIGGED NOSE GEAR DOWNLOCK SWITCH, PERFORMED SEVERAL EXTENSION AND RETRACTION TESTS, SYS CHECKED OK. ACFT RELEASED BACK TO SERVICE.

Part: CIRCUIT BREAKER — UNSERVICEABLE (AVIONICS) · airframe 21,172 hrs

PREFLIGHT, CREW REPORTED AVIONICS MASTER SWITCH INOPERATIVE. MX REMOVED AND REPLACED CIRCUIT BREAKER SWITCH. SYS CHECKS OK. ACFT RELEASED BACK TO SERVICE.

Part: ENGINE — FAILED (LEFT) · airframe 20,796 hrs

ON FINAL APPROACH, PILOT REPORTED LEFT ENGINE STARTED TO SPUTTER, AND RUN ROUGH, FOLLOWED BY SEVERE VIBRATION AND ENGINE STOPPAGE. MAINTENANCE FOUND CATASTROPHIC FAILURE OF THE LEFT ENGINE WITH A LARGE HOLE IN THE TOP ENGINE CASE FROM CONNECTING ROD PENETRATION. FAILURE ALSO DAMAGED TOP ENGINE COWLING. LEFT ENGINE WAS REPLACED, COWL REPAIRED AND AIRCRAFT WAS RETURNED TO SERVICE. ENGINE SENT TO MANUFACTURER FOR TEARDOWN TO DETERMINE PROBABLE CAUSE OF ENGINE FAILURE.

Part: LIMIT SWITCH — UNSERVICEABLE (HEATER) · airframe 20,552 hrs

CREW REPORTED SMOKE IN THE COCKPIT. MAINTENANCE INSPECTED AIRCRAFT, DETERMINED SOURCE OF SMOKE TO BE FROM AIRCRAFT HEATER DUCT LIMIT SWITCH. MAINTENANCE REMOVED AND REPLACED HEATER DUCT LIMIT SWITCH. AIRCRAFT RETURNED TO SERVICE.

Part: ENGINE — FAILED (RIGHT) · airframe 18,336 hrs · 13,922 cycles

RIGHT ENGINE FAILURE ON 1/2 MILE FINAL TO RUNWAY 25 AT PVC, CREW FEATHERED ENGINE AND LANDED. LATER INSPECTION ON 5-27-07 FOUND INTERNAL FAILURE IN THE RIGHT ENGINE. ENGINE REMOVED AND REPLACED ON 5-28-07. A/C RETURNED TO SERVICE AND ENG TO BE SENT TO MANUFACTURE FOR INVESTIGATION.

Part: ENGINE — FAILED (ZONE 400) · airframe 18,336 hrs · 13,922 cycles

RIGHT ENGINE FAILURE ON 1/2 MILE FINAL TO RUNWAY 25 AT PVC, CREW FEATHERED ENGINE AND LANDED. LATER INSPECTION ON 5-27-07 FOUND INTERNAL FAILURE IN THE RIGHT ENGINE. ENGINE REMOVED AND REPLACED ON 5-28-07. A/C RETURNED TO SERVICE AND ENG TO BE SENT TO MANUFACTURE FOR INVESTIGATION.

Part: SEAT — BROKEN (CABIN) · airframe 11,500 hrs

PILOT REPORTED FIXED BACK DOUBLE PASSENGER SEAT BROKEN. MAINTENANCE FOUND SEAT SEPARATED FROM PEDASTAL. REMOVED AND REPLACED SEAT AND SENT BACK TO ORIGINAL MFG FOR REPAIR. SEAT WAS INSTALLED UNDER AVIATION FABRICATOR STC SA2716CE. (K)

Part: MASTER SWITCH — BURNED (LT SWITCH PANEL)

CLIMBING THROUGH 1000 FEET, CREW NOTICED SMOKE COMING FROM AVIONICS MASTER SWITCH, TURNED OFF SWITCH, TURNED ON ALTERNATE AVIONICS SWITCH, LANDED WITHOUT INCIDENT. MECHANIC REMOVED OLD, REPLACED SWITCH.

Part: SEAL — LEAKING (RT SUB WING)

AFTER DEPARTURE, CREW SMELLED FUEL AND RETURNED TO LAND, LANDING WITHOUT INCIDENT. MAINTENANCE FOUND HEATER FUEL FILTERS LEAKING. REMOVED AND REPLACED GASKET. OPS AND LEAK CHECKED OK. AIRCRAFT RELEASED FOR RETURN TO SERVICE. (X)