N820DC

Part: SKIN — CORRODED (ZONE 100) · airframe 41,293 hrs · 44,202 cycles

A/B/E CHECK FOUND BELLY CORROSION

Part: DAMPER — FAULTED (ZONE 300) · airframe 60,823 hrs · 43,744 cycles

REMOVED AND SERVICED ELEVATOR DAMPER AND REINSTALLED PER SA227 MM CH 27-30-10 PERFORMED CABLE TENSION INSPECTION PER SA22X TC 27.920

Part: BLADE — CRACKED (PROPELLER) · airframe 40,383 hrs · 43,305 cycles

DURING AIRCRAFT INSPECTION A SPANWISE CRACK MEASURING APPROXIMATELY 6 INCHES LOCATED MID-SPAN AND APPROCIMATELY MID-CHORD WAS DETECTED BY VISUAL INSPECTION ON THE AFT FACE OF ONE PROPELLER BLADE. THE PROPELLER WAS REMOVED FOR REPAIR/OVERHAUL.

Part: UNKNOWN — UNKNOWN (UNKNOWN) · airframe 38,194 hrs · 41,223 cycles

PILOT REPORTED RH ENGINE FIRE LIGHT CAME ON IN FLIGHT, RH ENGINE FIRE BOTTLE WAS DISCHARGED. MAINTENANCE BLED PORT FOR ANTI-ICE VALVE, REPLACED GASKETS, COMPLETED POWER RUNS FOR RH ENGINE. INSTALLED OVERHAULED FIRE BOTTLE ASSEMBLY. GROUND OPS TEST GOOD, NO FAULTS FOUND.

Part: ACCUMULATOR — DAMAGED · airframe 36,584 hrs · 39,572 cycles

TOTAL HYDRAULIC FAILURE REPORTED BY PILOT WITH FLUID LEAKING FROM LEFT WHEEL WELL. MX REMOVED A FAILED HYDRAULIC ACCUMULATOR AND REPLACED WITH OVERHAULED ACCUMULATOR WITH NO DEFECTS NOTED. OPS CHECK WAS GOOD, WORK PERFORMED IN REF TO SA227 29-10-40.

Part: BELLCRANK — BROKEN (PAX DOOR) · airframe 35,981 hrs · 38,774 cycles

INSPECTOR FOUND BELLCRANK BROKEN AT GAS STRUT ATTACHMENT LUG.

Part: LINE — LEAKING (HYD SYSTEM) · airframe 35,896 hrs · 38,661 cycles

FLIGHT CREW HAD RIGHT HYDRAULIC LIGHT ILLUMINATED IN FLIGHT CRUISE AND FOLLOWED CHECKLIST FOR SINGLE HYDRAULIC PRESSURE LIGHT INDICATION. CREW STARTED DESCENT AND THE LEFT HYDRAULIC PRESSURE LIGHT CAME ON. CREW WAS ABLE TO LAND AT DESTINATION AND TAXI TO GATE WITHOUT FURTHER INCIDENT. MX INSPECTED AND FOUND HYDRAULIC PRESSURE LINE AFT OF FIREWALL LOOSE. MX TIGHTENED HYDRAULIC PRESSURE LINE AND PERFORMED ENGINE GROUND RUNS, OPERATIONS AND LEAK CHECKS WERE GOOD.

Part: TURBINE BLADES — FAILED (RIGHT ENGINE) · airframe 35,889 hrs · 38,650 cycles

FLIGHT CREW REPORTED LOUD BANG AND ENGINE POWER LOSS DURING CLIMB. FLIGHT CREW SECURED ENGINE AND LANDED SAFELY. MX FOUND ENGINE WOULD NOT TURN. PRELIM BORESCOPE INSPECTION FOUND FAILURE OF SEVERAL SECOND STAGE TURBINE BLADES. NO SIGNIFICANT DAMAGE TO UPSTREAM COMPONENTS WAS NOTED DURING THE BORESCOPE INSPECTION LEADING MX TO CONCLUDE THAT THE ROOT CAUSE OF THE FAILURE LIES IN THE FAILURE OF ONE OR MORE SECOND STAGE TURBINE BLADES.

Part: NOZZLE — BROKEN (GEARBOX) · airframe 35,324 hrs · 37,896 cycles

CARRIER RECIEVED REPORT OF BAD SOAP SAMPLE. CARRIER DISASSEMBLED ENGINE GEARARBOX AND FOUND BROKEN OIL NOZZLE ASSEMBLY IN INTERMEDIATE HOUSING AND GEAR ASSEMBLY - ACCESSORY GEAR AND DRIVE IDLER HOUSING ASSEMBLY.

Part: OIL JET — BROKEN (ENGINE) · airframe 35,306 hrs · 37,884 cycles

PILOT REPORTED THAT IN CRUISE FLIGHT THE ENGINE BRIEFLY INDICATED A RISE IN TORQUE FOLLOWED BY LOSS OF POWER. PILOT SECURED ENGINE AND RETURNED TO APA. MX UNABLE TO START ENGINE FOR TROUBLESHOOTING, FOUND FUEL PUMP DRIVE NOT TURNING. ACCESSED GEARBOX AND FOUND NUMEROUS DAMAGED GEARS/BEARINGS DUE A BROKEN OIL JET (P/N 3103581-1) - THE OIL JET BROKE OFF AND CAUSED FOD DAMAGE TO NUMEROUS COMPONENTS INCLUDING 1ST IDLER GEAR, 2ND IDLER GEAR, SPUR GEAR ASSY/BEARING, INTERMEDIATE SCAVENGE PUMP (CONTAMINATED W/ METAL PARTICLES), COMPRESSOR BEARING (CONTAMINATED), AND OTHER MINOR COMPONENTS. LIMITED GEARBOX REPAIR COMPLETED.

Part: LANDING GEAR — MALFUNCTIONED (NOSE) · airframe 35,203 hrs · 37,771 cycles

FLIGHT CREW REPORTED THAT THE NOSE GEAR WAS SLOW TO INDICATE DOWN AND LOCKED AFTER SELECTING GEAR DOWN. NORMAL LANDING CONDUCTED AFTER NOSE GEAR DOWN AND LOCKED INDICATION CAME ON. TROUBLESHOT THE AIRCRAFT AND CONDUCTED FUNCTIONAL TESTING. NO DEFECTS WERE FOUND. OPEN

Part: ENGINE — FAILED (NR 1) · airframe 31,935 hrs · 34,073 cycles

AFTER TAKEOFF, FIRST OFFICER CONFIGURED ACFT FOR CLIMB. SECOND OFFICER NOTICED SPLIT IN TORQUE INDICATION, SHORTLY FOLLOWED BY LOSS OF ENGINE POWER. SHUTDOWN ENGINE. DECLARED EMERGENCY AND RETURNED TO DEPARTURE AND MADE SAFE LANDING. MX R & R NR 1 ENGINE. OPEN

Part: WIRE — BURNED · airframe 31,093 hrs · 33,331 cycles

ENROUTE, PILOT BECAME AWARE OF SMOKE FROM AROUND RT SIDE CB PANEL AND IN CABIN. PILOT DECLARED EMERGENCY AND LANDED. ACFT WAS INSPECTED AND FERRIED WITH NO ISSUES. UPON INSPECTION AND TEST: FWD COAT CLOSET DIRECTLY BEHIND COPILOTS SEAT EVAPORATOR SHROUD WAS REMOVED. INSPECTION REVEALED AN ELECTRICAL BURN FROM THE POWER WIRES AGAINST THE EVAPORATOR SHROUD. THE AIR DRAW HOLE IN THE AFT SIDE OF AFT BULKHEAD HAD BEEN BENT BY A PASSENGER SITTING IN THE FORWARD RT SEAT. THE AFT PORTION OF THE EVAPORATOR SHROUD WAS BEND AND PINCHED POWER WIRE TO EVAPORATOR COMPRESSOR. A METAL GRADE WAS INSTALLED TO PREVENT INADVERTANT DISTORTION FROM PASSENGERS TO EVAPORATOR/COMPRESSOR.