N740CA

Part: WIRE — CHAFED (PTT SWITCH) · airframe 27,613 hrs · 12,228 cycles

THE PILOT REPORTED A BURNING SMELL AFTER THE AUTOPILOT CB POPPED DURING FLIGHT. MAINTENANCE INSPECTED AND FOUND CHAFFED WIRING AT THE PTT SWITCH. THE WIRES WERE REPAIRED WITH NO FURTHER DEFECTS NOTED.

Part: CABLE ASSY — FAILED (THROTTLE) · airframe 26,254 hrs

PILOT REPORTED RIGHT ENGINE THROTTLE STUCK AT 35 INCHES MAP. THE ENGINE WAS SHUT DOWN AND THE AIRCRAFT RETURNED TO THE FIELD WITHOUT INCIDENT. INSPECTION FOUND THE RIGHT THROTTLE CABLE PROPERLY ATTACHED AT BOTH ENDS, AND THE CABLE FAILED INTERNALLY. THE CABLE WAS REPLACED WITH NO FURTHER DEFECT NOTED.

Part: DOOR FRAME — CORRODED (FUSELAGE) · airframe 26,093 hrs · 9,179 cycles

WHILE CONDUCTING OTHER MAINTENANCE, AN AREA OF CORROSION WAS NOTED ON THE FUSELAGE FRAME ASSEMBLY AT FS 214.00, JUST ABOVE THE 501110-12 STRIKER PLATE FOR THE LOWER PASSENGER DOOR PIN. THE 501110-12 STRIKER PLATE WAS REMOVED FOR FURTHER INSPECTION. UPON REMOVAL OF THE STRIKER PLATE, MORE CORROSION WAS DISCOVERED. THIS AREA OF CORROSION WAS MEASURED AT 2.12 HIGH BY .77 WIDE, WITH A DEPTH OF .058. THE FUSELAGE FRAME AND STRIKER PLATE WILL BE REPLACED WITH FACTORY NEW PARTS.

Part: CROSSBEAM — CHAFED (RT NACELLE) · airframe 26,093 hrs · 9,179 cycles

DURING MAINTENANCE, CHAFING DAMAGE WAS FOUND ON THE RIGHT NACELLE CROSSOVER BEAM.

Part: FITTING — CORRODED (RT NACELLE) · airframe 26,093 hrs · 9,179 cycles

DURING MAINTENANCE, CORROSION WAS FOUND ON THE UPPER SURFACE OF THE RIGHT NACELLE OUTBOARD FITTING, AROUND THE FASTENER HOLES OF THE TOP FORWARD FACE OF THE FITTING, JUST FORWARD OF THE FIREWALL. THE DEPTH OF THIS CORROSION IS .019 IN. THE FITTING WAS REPLACED.

Part: ROTOR COIL — DAMAGED (NR 4 CYLINDER) · airframe 25,426 hrs

CREW REPORTED ENGINE ROUGHNESS IN FLIGHT AT POWER REDUCTION FOR CRUISE AND MIXTURE FULL RICH. THE ACFT LANDED SAFELY AT ITS INTENDED DESTINATION WITH NO ISSUE. INSPECTION DISCOVERED LOW DIFFERENTIAL COMPRESSION CHECK RESULT AT CYLINDER NR 4 OF THE LT ENGINE. A BORESCOPE INSPECTION WAS PERFORMED. THE VALVE DOES NOT APPEAR TO EXHIBIT THE COMMON GREEN COLOR INDICATING HEAT DAMAGE. DIFFERENTIAL COMPRESSION CHECK AND BORESCOPE INSPECTION PERFORMED IAW M-O MANUAL. UPON REMOVAL OF THE ROCKER BOX COVER TO FACILITATE REPLACEMENT OF THE CYLINDER, THE EXHAUST VALVE ROTOCOIL WAS FOUND TO BE SEVERELY DAMAGED.

Part: CYLINDER — DAMAGED (RT ENGINE) · airframe 25,339 hrs

CREW REPORTED A STRONG VIBRATION FROM RT ENGINE AS MIXTURE WAS REDUCED BELOW 100 PPH. THE CREW ENRICHED THE MIXTURE AND ELECTED TO DIVERT TO KHYA AS A PRECAUTION. INSPECTION DISCOVERED LOW DIFFERENTIAL COMPRESSION, 0 PSI/80PSI, AT CYLINDER POSITION NUMBER 1 OF THE RT ENGINE. A BORESCOPE INSPECTION WAS PERFORMED AND EXHAUST VALVE FACE EXHIBITED CLASSIC SIGNS OF OVERHEATING. THERE IS ALSO EVIDENCE OF EXHAUST VALVE SEAT RECESSION. IMAGES OF EXHAUST VALVE AND SEAT WILL BE PROVIDED AS A SUPPLEMENT TO THIS RECORD TO ILLUSTRATE DAMAGE. DIFFERENTIAL COMPRESSION CHECK AND BORESCOPE PROCEDURES WERE PERFORMED IN ACCORDANCE WITH THE LATEST REVISION OF CMI M-0 MANUAL. THESE INSPECTION PROCEDURES WERE LAST PERMED 34.2 FLIGHT HOURS PRIOR TO THIS EVENT. THIS CYLINDER WAS PURCHASED NEW AND HAS ACCUMULATED 1110.3 HOURS OF OPERATION IN 13 MONTHS. THE INTAKE AND EXHAUST LIFTER ASSOCIATED WITH THIS CYLINDER WERE REPLACED AS A PRECAUTION.

Part: INDICATOR — FAULTY (COCKPIT) · airframe 25,293 hrs · 7,749 cycles

PILOT REPORTED SMELL OF SMOKE IN COCKPIT UPON ACTIVATION OF WEATHER RADAR. MAINTENANCE INSPECTED AND DETERMINED TO BE DUE TO FAULTY INDICATOR. SYSTEM WAS PLACED ON MEL.

Part: EXHAUST VALVE — DAMAGED (NR 2 CYLINDER) · airframe 24,843 hrs

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

Part: EXHAUST VALVE — DAMAGED (NR 5 CYLINDER) · airframe 24,843 hrs

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

Part: EXHAUST VALVE — DAMAGED (NR 1 CYLINDER) · airframe 24,843 hrs

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

Part: CLAMP — LOOSE (PROP CONTROL) · airframe 24,632 hrs · 6,643 cycles

PILOT REPORTED LT PROP LEVER DOES NOT CONTROL RPM, LT PROP WILL NOT FEATHER. MAINTENANCE INSPECTED AND FOUND THE LT PROPELLER GOVERNOR CONTROL CABLE BRACKET ATTACH CLAMPS TO BE LOOSE. MAINTENANCE ADJUSTED AND SECURED LT PROP GOVERNOR CABLE BRACKET IAW AMM CH 61.

Part: ROD — SEVERED (TE FLAP) · airframe 24,246 hrs · 5,995 cycles

PILOT REPORTED ON APPROACH, WHEN FLAPS DEPLOYED TO 30 DEGREES THE ACFT ROLLED AGGRESSIVELY TO THE RIGHT. INSPECTED & FOUND THE RT FLAP OTBD FLAP ROD SEVERED. R & R THE FLAP ROD, OPERATIONALLY CHECKED GOOD.

Part: GOVERNOR — DEFECTIVE (RT PROPELLER) · airframe 24,207 hrs · 5,907 cycles

PILOT REPORTED RT PROPELLER OVERSPEED INDICATION ON CLIMB OUT, THEN DIFFICULTY CONTROLLING THE PROPELLER AT A STEADY RPM AFTER THAT POINT. R & R THE RT ENG PROPELLER GOVERNOR, OPERATIONAL & LEAK CHECKED GOOD WITH NO FURTHER DEFECTS AT THAT TIME.

Part: PANEL — OPEN (LT WING) · airframe 23,832 hrs · 5,227 cycles

PILOT REPORTED WING LOCKER LT SIDE OPENED IN FLIGHT. INSPECTED LATCH OF LT WING LOCKER WITH NO DEFECTS FOUND. REMOVED LATCH COVER, INSPECTED ALL PINS & RODS, INSPECTED HINGES, INSPECTED SAFETY LATCH WITH NO DEFECTS FOUND.

Part: LATCH — UNSECURE (LT WING) · airframe 23,746 hrs · 5,056 cycles

LT WING LOCKER OPENED IN FLIGHT. INSPECTED & SECURED THE LT WING LOCKER LATCH. OPERATIONALLY CHECKED GOOD.

Part: CALIPER — FAILED (LT BRAKE) · airframe 23,701 hrs · 5,056 cycles

THE LT BRAKE STUCK & THE RT BRAKE FAILURE DURING TAXI. VISUALLY CHECKED THE RT BRAKE, SERVICED MASTER CYLINDER & BLED BRAKE SYS. REPLACED LT BRAKE CALIPER & SERVICED BRAKE SYS. BOTH SIDES OPERATIONALLY CHECKED GOOD.

Part: INDICATOR — FAILED (WEATHER RADAR) · airframe 23,604 hrs · 4,695 cycles

PILOT REPORTED A FAINT SMELL AFTER WEATHER RADAR STOPPED WORKING INFLIGHT. THE CB DID NOT POP. R & R WEATHER RADAR INDICATOR & TRANSCEIVER ANTENNA WITH NO FURTHER SMELLS NOTED.

Part: DRAG BRACE — CRACKED (NLG) · airframe 21,624 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.