N84EA

Part: CONTROL CABLE — CHAFED (LT AILERON) · airframe 5,982 hrs · 3,559 cycles

DURING ROUTINE INSPECTION THE LT AILERON CABLE WAS FOUND CHAFED WHERE THE CABLE TRAVELS THROUGH THE INBD CLOSEOUT RIB FOR THE INBD L/E SECTION INBD OF WING BS BL54.85. THE AILERON CABLE HAD BEEN CHAFING OF THE ONBOARD EDGE OF THE WING SPAR HEAT SHIELD. A SIGNIFICANT NUMBER OF STRANDS WERE FOUND TO BE BROKEN.

Part: SENSOR — FAILED (BATTERY TEMP) · airframe 5,781 hrs · 3,441 cycles

DURING TAKEOFF, CREW NOTICED RISE IN BATTERY NR 2 TEMPERATURE, FOLLOWED CHECKLIST ISOLATING NR 2 BATTERY. CREW CONTINUED WITH TAKEOFF WITHOUT INCIDENT. BATTERY TEMPERATURE CONTINUED TO RISE, CREW MADE THE DECISION TO RETURN TO DEPARTURE, DECLARING AN EMERGENCY SITUATION. ONCE ON THE GROUND FIRE PERSONNEL TEMPERATURE CHECKED THE BATTERY AT 77F. AT THIS TIME IT WAS NOTED AS A FAILURE OF THE TEMPERATURE SENSOR IN THE BATTERY CASE.

Part: SENSOR — FAULTY (NR 1 BATTERY) · airframe 3,405 hrs · 2,105 cycles

ON ARRIVAL INTO KSAT, BAT NR 1 OVERTEMP LIGHT ON, EMERGENCY DECLARED, UNEVENTFUL LANDING ACCOMPLISHED. MAINTENANCE FOUND BAD TEMP SENSOR AND REPLACED WITH NEW SENSOR.

Part: VALVE — LEAKING (MLG)

ON TAKEOFF, LANDING GEAR WOULD NOT RETRACT. AIRCRAFT LANDED UNEVENTFULLY. TROUBLESHOOTING REVEALED VALVE ON EMERGENCY PNEUMATIC RESERVOIR (BLOW DOWN BOTTLE) LEAKED, PRESSURIZING DOWN SIDE OF LANDING GEAR RETRACTION SYSTEM. ASSEMBLY WAS REMOVED AND SHIPPED OUT FOR REPAIR.

Part: SPRING — BROKE (THROTTLE)

PILOT REPORTED HE HEARD A 'POP' DURING ENGINE SHUT DOWN AND LEFT THROTTLE TRIGGER LOST TENSION. FOUND SPRING BROKEN AND REPLACED UNIT. FAILURE OF THIS SPRING COULD ALLOW THROTTLE TO MAKE A 'CUT-OFF' INADVERTENTLY INSTEAD AT IDLE.

Part: ENGINE — MALFUNCTIONED (RT NACELLE)

PILOT REPORTED HOT OIL SMELL COMING FROM OVERHEAD VENTS DURING POSITIONING FLIGHT FOR MAINTENANCE. TROUBLESHOOTING SHOWED SMELL COMING FROM RIGHT ENGINE.

Part: SEAT RAIL — WORN (COPILOT RT OTBD)

DURING PHASE 5 INSPECTION, FOUND HOLES WORN TO LIMITS AT CO-PILOT'S RIGHT SEAT RAIL HATCH. SPLICED IN NEW SECTION OF SEAT RAIL IAW CESSNA 550 SRM FIGURE 801.

Part: GROMMET ASSY — BROKEN (COMB LINER)

RIGHT IGNITER WAS EXTREMELY DIFFICULT TO REMOVE. WHEN REMOVED PARTS WERE HEARD TO FALL INSIDE COMBUSTION CHAMBER. BORESCOPE INSPECTION REVEALED PORTIONS OF BOTH LEFT AND RIGHT GROMMET ASSEMBLIES LYING IN COMBUSTION CHAMBER. ENGINE HAS BEEN DISASSEMBLED TO HSI LEVEL AND REPAIRS ARE PENDING.

Part: SWITCH — STUCK (HYD PRESS)

ON TAKEOFF, 'HYD PRESS ON'. LIGHT STAYED ON AFTER LANDING GEAR RETRACTION. PILOT RAN CHECKLIST ITEMS AND DIVERTED TO FJJ. TROUBLESHOOTING REVEALED SWITCH S89 STUCK. SWITCH WAS REPLACED AND FUNCTIONAL TEST COMPLETED SATISFACTORILY.

Part: WINDOW — CRACKED (COCKPIT RT SIDE)

DURING PRISM INSPECTION OF CO-PILOT'S WINDOW, FOUND 4 FASTENER HOLES CRACKED AT UPPER FORWARD. CRACK CONNECTS CENTER 2 FASTENERS. WINDOW IS TO BE REPLACED.

Part: SHROUD SEGMENT — GOUGED (HP TURBINE)

DURING PHASE 25/HOT SECTION INSPECTION, ALL HIGH PRESSURE TURBINE SHROUD SEGMENT WIRE FOUND GOUGED. DAMAGE WAS CAUSED BY FAILURE OF DEFLECTOR RING AND RESULTING HIGH TURBINE BLADE DAMAGE. ALL SHROUD SEGMENTS WERE REPLACED.

Part: BLADE — DAMAGED (HP TURBINE)

DURING PHASE 25/HOT SECTION INSPECTION, ALL 71 HIGH TURBINE BLADES WERE FOUND NICKED, DENTED AND BROKEN BY IMPACT DAMAGE FROM DEFLECTOR - RING FAILURE. NUMEROUS BLADES WERE MISSING FORWARD ONE-QUARTER OF OUTBOARD LEADING EDGE. NO COCKPIT INDICATION WAS NOTED AS TIP CLEARANCES FOR REMAINDER OF BLADE WAS STILL IN TOLERANCE. ALL BLADES WERE REPLACED WITH NEW.

Part: RING SUPPORT — BROKEN (GAS GEN CASE)

DURING PHASE 25/HOT SECTION INSPECTION, IMPACT DAMAGE WAS NOTED ON THE NR 2 TURBINE BLADES. FURTHER DISASSEMBLY REVEALED 2 SECTIONS OF THE DEFLECTOR RING HAD BROKEN OFF. THESE SECTIONS WERE APPROXIMATELY 1.50 INCHES LONG AND LOCATED AT TEN O'CLOCK AND 1:30 O'CLOCK IN LINE WITH DIFFUSER PIPES. THE DEFLECTOR RING WAS ALSO BROKEN IN HALF AT THE TEN O'CLOCK POSITION. ONE MISSING RING SECTION WAS FOUND LODGED IN THE GAS GENERATOR CASE. THE OTHER TRAVELLED AFT RESULTING IN DAMAGE TO THE HIGH TURBINE ASSY AND LOW TURBINE BALANCE ASSY. NO COCKPIT INDICATION OF FAILURE WAS NOTED.

Part: BLADE — DAMAGED (LP TURBINE)

DURING PHASE 25/HOT SECTON INSPECTION, IMPACT DAMAGE WAS FOUND ON 2ND STAGE LOW TURBINE. THIS WAS CAUSED BY FAILURE OF DEFLECTOR RING. UNIT WAS SENT TO P & WC, DISASSEMBLED, BLENDED AND REASSEMBLED. NO COCKPIT INDICATIONS OF DAMAGE WERE NOTED PRIOR TO HOT SECTION INSPECTION.

Part: TIRE — DEFECTIVE (BALANCE PATCH)

WHILE MOVING AIRCRAFT INTO HANGAR, NOSE TIRE MADE ODD NOISE. DISASSEMBLY REVEALED BALANCE PATCH INSIDE TIRE HAD COME LOOSE. PATCH WAS FREE TO CHANGE POSITION. SUBMITTER SUSPECTS POOR QUALITY OF ADHESIVE. MANUFACTURER WAS NOTIFIED OF PROBLEM. LANDINGS, 41.