N58

Part: WARNING SYSTEM — ACTIVATED (COCKPIT) · airframe 11,853 hrs · 5,675 cycles

"BLEED AIR R" ANNUNCIATOR ILLUMINATED IN FLIGHT. TURNED OFF R BLEED AIR PER CHECKLIST.

Part: STATIC INVERTER — MALFUNCTIONED (ZONE 400) · airframe 11,626 hrs · 5,575 cycles

RIGHT INVERTER BLINKED OFF, VOLTS WENT TO ZERO, RED LIGHT CAME ON, ELECTRICAL POWER ANNUNCIATOR MASTER CAUTION CAME ON. THEN RESET WITH OUT ANY PILOT ACTION.

Part: ENGINE — SHUTDOWN (LEFT) · airframe 11,516 hrs · 5,521 cycles

FL 320 - LEFT ENGINE SHUDDERED AND SHUT DOWN LEFT AMBER & WHITE COMPUTER LIGHTS. OIL PRESSURE AND FUEL PRESSURE LIGHTS ON. N1 APPROX 9%, N2 APPROX 25%. ZERO OIL PRESSURE. RAN SHUTDOWN CHECKLIST. NO RESTART ATTEMPTED.

Part: CONTROL PANEL — DEFECTIVE (COCKPIT) · airframe 11,434 hrs · 5,488 cycles

LEFT MAIN GEAR POSITION INDICATOR LIGHT INTERMITTENT. REPLACING THE LANDING GEAR CONTROL PANEL CORRECTED THE DISCREPANCY.

Part: CONTROL UNIT — FAILED (TAILCONE) · airframe 10,051 hrs · 4,792 cycles

BOTH BLEED AIR LIGHTS ILLUMINATED 17 MINS INTO FLIGHT. REPLACEMENT OF THE TAIL CONE OVERHEAT CONTROL UNIT SOLVED THE ISSUE.

Part: WARNING SYSTEM — ACTIVATED (COCKPIT) · airframe 10,018 hrs · 4,775 cycles

LEFT & RIGHT BLEED AIR LIGHTS ANNUNCIATED AFTER TAKEOFF, MCT POWER, WHEN NAC HEATS SELECTED ON.

Part: WARNING SYSTEM — ACTIVATED (COCKPIT) · airframe 10,018 hrs · 4,775 cycles

LEFT & RIGHT BLEED AIR LIGHTS ANNUNCIATED AFTER TAKEOFF, MCT POWER, WHEN NAC HEATS SELECTED ON.

Part: DOOR — CRACKED (MLG DOORS) · airframe 10,006 hrs · 4,766 cycles

WHILE ACFT WAS OUT OF SERVICE FOR 12 MONTH SERVICING, CRACKS WERE FOUND ON BOTH LT & RT LG DOORS, STEMMING APPROX 1" OUT FROM OTBD MOST ATTACH HOLE.

Part: WARNING SYSTEM — ACTIVATED (COCKPIT) · airframe 9,830 hrs · 4,692 cycles

LEFT & RIGHT BLEED AIR LIGHT ILLUMINATED, SIMULTANEOUSLY THEN EXTINGUISH SOON AFTER TURNING BOTH BLEED AIR SWITCHES TO OFF.

Part: GASKET — LEAKING (BLEED AIR SYS) · airframe 9,827 hrs · 4,690 cycles

BLEED AIR LT & RT ILLUMINATED. EXTINGUISHED AFTER FOLLOWING ABNORMAL CHECKLIST. ACFT HAD NOT FLOWN FOR SEVERAL MONTHS. REPLACED LEAKING SOV GASKET.

Part: O-RING — CUT (HYDRAULIC SYS) · airframe 9,342 hrs · 4,465 cycles

AFTER NR 1 ENG START CREW STARTED TO SMELL AN ODOR, STARTED NR 2 ENG & SHUTDOWN APU, ODOR GOT WORSE. PILOT CALLED MX TO THE ACFT, MX RODE WITH PILOTS TO RUN-UP AREA. PILOT INCREASED POWER TO 56% N1, TURNED ACFT AIR CONDITIONER TO FULL HOT & ACFT FILLED WITH BLUE SMOKE IMMEDIATELY. TROUBLE SHOT & O RING CUT ON RESERVOIR PRESS CHECK VLV. FOUND CHECK VLV TO BE OLD STYLE. COMPLIED WITH SB 60-29-8 WHICH REPLACES THE CHECK VLV WITH A LOW PRESS ZERO LEAKAGE VLV.

Part: WARNING SYSTEM — FALSE ACTIVATION (COCKPIT) · airframe 9,067 hrs · 4,346 cycles

BLEED AIR LT & BLEED AIR RT ALONG WITH THE MASTER WARNING ANNUNCIATORS ILLUMINATED. THE EMERGENCY CHECKLIST, TAB 4 PAGE E7, WAS COMPLIED WITH & WHEN THE RT BLEED AIR SWITCH WAS TURNED OFF THE BLEED AIR LT & BLEED AIR RT ANNUNCIATORS WENT OUT, LANDED WITHOUT INCIDENT. RAN BOTH ENGS TO TAKEOFF POWER WITH BLEED VLVS SELECTED OPEN. LEAK CHECKED ENVIRONMENTAL CONTROL SYS WITH NO LEAKS NOTED. LT & RT BLEED AIR ANNUNCIATOR LIGHTS REMAINED EXTINGUISHED THROUGHOUT CHECKS.

Part: UNKNOWN — ODOR (CABIN) · airframe 8,863 hrs · 4,252 cycles

HEAVY ODOR OF FUMES IN CABIN DURING TAKEOFF. FUMES DISSIPATED AFTER BLEED AIR SWITCH & CABIN AIR SWITCH TURNED OFF. DURING BEFORE TAXI CHECKLIST, THE LT BLEED AIR PASSED ONLY AFTER SEVERAL ATTEMPTS. RUN UP APU & BOTH ENGS, SET CABIN AIR ON & ODOR DISSIPATED AFTER HALF HOUR RUN. LT BLEED AIR OPERATIONS CHECKED GOOD IAW MM CH 21.

Part: WARNING LIGHT — ILLUMINATED (MLG) · airframe 8,863 hrs · 4,252 cycles

BOTH MAIN GEAR "UNSAFE" LIGHTS REMAINED ILLUMINATED FOLLOWING GEAR RETRACTION. REMAINED ILLUMINATED AFTER GEAR EXTENSION.

Part: UNKNOWN — SMOKE (COCKPIT/CABIN) · airframe 7,705 hrs · 3,694 cycles

BOTH LEFT AND RIGHT BLEED AIR LIGHTS ILLUMINATED FOLLOWED BY SMOKE AND FUMES IN THE COCKPIT/CABIN. APPROX 15 MINUTES AFTER TAKEOFF, DURING FINAL LEVEL OFF AT FL 280, BOTH LT & RT BLEED AIR LIGHTS ILLUMINATED SIMULTANEOUSLY INDICATING A TAIL CONE OVERHEAT CONDITION. ACCOMPLISHED CHECKLIST AND LIGHTS WENT OUT WITH LEFT BLEED IN EMERGENCY AND RIGHT BLEED ON. LIGHTS ILLUMINATED AGAIN WHEN POWER WAS ADVANCED. SMOKE ENTERED COCKPIT AFTER 15 MINUTES OF BEGINNING EMERGENCY CHECKLIST. ACCOMPLISHED UNEVENTFUL OVERWEIGHT LANDING. INSPECTED TAIL CONE BLEED OVERHEAT DETECTION AND CHECKED FOR BLEED AIR LEAK. RAN ENGINE AND APU AT MCR. ALL SYSTEMS CHECKED GOOD.

Part: ENGINE — POWER LOSS (RIGHT) · airframe 7,312 hrs · 3,502 cycles

APPROX 20 MIN INTO 2ND FLT, RT ENGINE ROLLED BACK TO IDLE DURING CLIMBOUT / LEVEL OFF AT 8900 MSL FOLLOWING LOW APPROACH. ROLLBACK WAS ACCOMPANIED BY SIGNIFICANT VIBRATION BUT NO ANNUNCIATORS. CREW BROUGHT RT THRUST LEVER TO IDLE, DECLARED AN EMERGENCY AND CONTINUED CLIMB TO 13,000 FT W/ RT ENGINE AT IDLE AND LEFT ENG AT MCT. LEVEL AT 13,000 AND 250 KIAS RT THRUST LEVER WAS BROUGHT UP TO APPROX 71 PERCENT TO MATCH LEFT. REMAINDER OF 20 MIN FLIGHT TO KBOI WAS UNEVENTFUL WITH ALL ENGINE PARAMETERS NORMAL. THE AIRCRAFT LANDED UNEVENTFULLY.

Part: UPLOCK SWITCH — DEFECTIVE (MLG) · airframe 6,951 hrs · 3,326 cycles

ON LOW LEVEL APPROACH GO AROUND, RAISED GEAR HANDLE TO UP POSITION. NO ACTION, 3 GREEN, NO RED INDICATION. RETURNED HANDLE TO DOWN POSITION. GEAR INDICATION REMAINED NORMAL FOR DOWN POSITION. ELECTED TO RETURN TO HOME BASE. CONDUCTED TOWER FLY-BY TO VERIFY GEAR DOWN. PROCEEDED WITH NORMAL UNEVENTFUL LANDING.

Part: SEAL — LEAKING (BLEED AIR SYS) · airframe 6,690 hrs · 3,213 cycles

WHILE AT CRUISE DUAL BLEED AIR LIGHT INDICATION (TAIL COMPARTMENT OVERHEAT WARNING). EMERGENCY / ABNORMAL CHECKLIST COMPLETED AND BLEED AIR SYSTEM ISOLATED. LIGHTS REMAINED ILLUMINATED AND PRECAUTIONARY, OVERWEIGHT LANDING MADE. LIGHTS WENT OUT APPROXIMATELY 20 MINUTES AFTER LANDING. FOUND SMALL LEAK AT BLEED AIR COUPLING DIST DUCT. REPLACED SEALS. REMOVED AND REPLACED RT FORWARD LOOP DETECTOR CONTROL BOX.

Part: MANIFOLD — LEAKING (RT BLEED AIR) · airframe 5,701 hrs · 2,793 cycles

IFR EN ROUTE, FL190, NOTICED "HOT AIR" TYPE OF ODOR. NO SMOKE OBSERVED. SHORTLY AFTER ODOR "BLEED AIR R" ANNUNCIATOR LIGHT ILLUMINATED. INITIATED EMERGENCY PROCEDURE (EP) "BLEED AIR LIGHT". AFTER COMPLETION OF "BLEED AIR LIGHT" CHECKLIST, INCLUDING RIGHT BLEED SHUT-OFF AND RIGHT ENGINE THRUST REDUCTION, BLEED AIR LIGHT EXTINGUISHED. REQUESTED IMMEDIATE RETURN TO KACY, BASED ON CONTINUED ODOR AND CONCERN THAT LEAK MAY NOT BE CONTAINED. LANDING WAS UNEVENTFUL WITH LOW TOUCHDOWN G'S AND MINIMAL BRAKE USAGE. GROUND CREW FOUND RT BLEED AIR MANIFOLD LOCATED AT LOWER AFT END OF ENGINE LEAKING.

Part: SKIN — CRACKED (FUSELAGE)

DURING INSPECTION, LEFT DELTA FIN WAS FOUND TO HAVE EXCESSIVE MOVEMENT ON THE LOWER SKIN. REMOVED FIN AND FOUND CRACK IN LOWER FIN ATTACHMENT, ADJACENT TO THE SCREW HOLES, UNDER FIN TO FUSELAGE ATTACH ANGLE. CRACK WAS THIRTEEN INCHES LONG. LOWER SKIN WAS ALSO DELAMINATED. THE INBOARD RIB HAD A CRACK SIX INCHES LONG JUST AFT OF THE LEADING EDGE. (M)

Part: CONTROL BOX — FAILED (RT ENG FIRE WARN)

ON DEPARTURE, CLIMBING THROUGH 11,000 MSL, RIGHT ENGINE FIRE LIGHT ILLUMINATED. ENGINE FIRE IN FLIGHT CHECKLIST ACCOMPLISHED. ADVISED PDX ATC, REQUESTED IMMEDIATE RECOVERY, EMERGENCY DECLARED. RIGHT ENGINE FIRE LIGHT REILLUMINATED THREE TIMES DURING APPROACH AND LANDING FOR APPROXIMATELY 5 SECONDS EACH TIME. REMOVED AND REPLACED RT ENGINE FIRE DETECTION CONTROL BOX.

Part: FLOAT VALVE — LEAKING (FUEL VENT)

DURING APPROACH, CONTROL TOWER ADVISED THAT A VAPOR TRAIL WAS OBSERVED FROM LT WING. AIRBORNE TECH CONFIRMED FUEL COMING FROM UNDER LT WING. FLT WAS DEVIATED TO AND LANDING MADE, WITH FIRE EQUIPMENT STANDING BY. FUEL FROM LT WING AND LEAK STOPPED. NORMAL LANDING/ NO PROBLEMS. REMOVED AND REPLACED LT FUEL VENT FLOAT VALVE IAW MFG MM. REFUELED, LEAK CHECKED GOOD. RETURNED TO SERVICE.

Part: CLAMP — LOOSE (VALVE DUCT)

AT APPROX 1604Z, DEPARTING RWY 13R WHILE CLIMBING THROUGH 9,000 FOR 25,000 FT, MCT POWER SELECTED, THE RIGHT ENGINE FIRE LIGHT ILLUMINATED. LEVEL OFF AT 22,000 FT INITIATED, ATC NOTIFIED. THE ENGINE FIRE LIGHT EXTINGUISHED, PRECAUTIONARY LANDING MADE AT BFI. NO FURTHER INDICATION OF AN ENGINE FIRE OBSERVED, THEREFORE, ENGINE WAS SHUTDOWN IN FLIGHT, CREW ELECTED TO BURN FUEL IN AN EFFORT TO AVOID OVERWEIGHT LANDING. AIRCRAFT REFERRED TO MAINTENANCE, CAUSE UNKNOWN AT THIS TIME. S/D - MAINTENANCE GROUND RAN ENGINE, FOUND BLEED AIR LEAK AT CLAMP HP AIR MIXING VALVE. LOOSENED CLAMP, INSPECTED AND RETORQUED. OPERATIONAL CHECK SATISFACTORY, NO LEAK DETECTED. (M)

Part: TUBE — CHAFED (ELBOW)

DURING C-CHECK INSPECTION, THE RIGHT MOTIVE FLOW LINE WAS FOUND CHAFFING THE FORWARD ENGINE BLEED AIR LINE IN THE PYLON AREA. THE TWO LINES WERE RUBBING METAL TO METAL. THIS FUEL LINE RUNS ABOUT 300 PSI AND THE BLEED LINE IS ABOUT 500 DEGREES. IPC REFERENCE 28-24-26 ITEMS NR 8 AND 34 OR 45. NOTED NO PROBLEM IN LEFT PYLON. APPARENT CAUSE, LINES AT INSTALLATION CAN BE INSTALLED BACKWARDS THUS CAUSING INTERFERENCE. BOTH LINES ARE PROPERLY INSTLALED WITH ELBOW AT ENGINE FIREWALL. (M)

Part: VALVE — MALFUNCTIONED (RT ENGINE)

OK - STRONG ODOR OF BURNING RUBBER COCKPIT IMMEDIATELY AFTER TAKEOFF. RIGHT ENGINE FIRE WARNING LIGHT ILLUMINATED IMMEDIATELY AFTER TAKEOFF. ENGINE SHUT DOWN AND RETURN SAFELY TO LAND. (M)

Part: FIRE LOOP — MALFUNCTIONED (RT ENGINE)

RIGHT ENGINE FIRE LIGHT ILLUMINATED IN FLIGHT. ENGINE POWER LEVER WAS BROUGHT BACK TO IDLE AND LIGHT EXTINGUISHED. RETURN TO STATION WITHOUT FURTHER INCIDENT. (M)