GRAND CANYON AIRLINES INC

Operated by GRAND CANYON AIRLINES INC (per NTSB report)

Operated by Grand Canyon Airlines, Inc. (per NTSB report)

Operated by Grand Canyon Airlines (per NTSB report)

Operated by Grand Canyon Airlines (per NTSB report)

Operated by Grand Canyon Airlines (per NTSB report)

WHILE IN FLIGHT, CREW SMELLED SMOKE. THE CREW OPENED THE BUS TIE AND ISOLATED THE ELECTRICAL POWER. ACFT RETURNED TO BASE WITHOUT FURTHER INCIDENT. MAINTENANCE INSPECTED ACFT AND FOUND 2 COMPONENTS BAD, BUT HAVE NOT DETERMINED YET IF THEY ARE RELATED. THE FM RADIO AND THE RT ATTITUDE INDICATOR. THE SHOP FINDINGS HAVE NOT COME BACK ON THESE ITEMS. THE ACFT WAS THOROUGHLY INSPECTED AND AN OPS CHECK FLIGHT OF 1 HR REVEALED NO MORE ISSUES.

PILOT TOOKOFF, THEN REPORTED THAT AT 400 FEET AGL AFTER TAKEOFF, CREW HEARD WEIRD NOISES AND FELT PITCH CHANGES. RIGHT TORQUE INDICATED HIGH, WITH RT PROP RPM FLUCTUATING. RIGHT ENGINE WAS SHUTDOWN AND CREW RETURNED TO DEPARTURE WITH NO FURTHER INCIDENT.

MFG INSTALLED NEW FIRST STAGE SUN GEAR, WITH NEW 1ST STAGE PLANET GEAR SET ASSY. ONE OF THE GEARS, HAD A BUSHING FAILURE, CAUSING THE GEAR TO SPIN AROUND. CAUSING CONTAMINATION OF THE OIL SYSTEM. GEAR HAD FOUR HRS OF TEST TIME ONLY SINCE NEW. REPAIR STATION INSTALLED THE GEARS DURING O/H AND DID NOT NOTICE ANY DEFECT IN THE GEAR AT THE TIME OF INSTALLATION. BUSHING FAILURE OCCURRED AFTER CUSTOMER INSTALLED THE ENGINE AND WAS PERFORMING A GROUND PERFORMANCE RUN. DURING THE PERFORMANCE RUN, THE OIL PRESSURE DROPPED TO 80 PSI. SHUTDOWN THE ENGINE AND REMOVED THE FILTER HOUSING TO ADJUST THE OIL PRESSURE. AT THIS TIME THEY NOTICED BRONZE-LIKE FLAKES IN THE OIL FILTER. THE CHIP DETECTOR WAS PULLED AND A SIGNIFICANT AMOUNT OF DEBRIS WAS NOTED. THE ENGINE WAS RETURNED TO THIS REPAIR STATION AND AN INVESTIGATION REVEALED THE BUSHING HAD SPUN IN THE GEAR CAUSING OIL CONTAMINATION. NO OIL STARVATION WAS OBSERVED IN ANY OF THE GEARS WITHIN THE RGB/AGB, ELIMINATING THE POSSIBILITY OF GROUND CREW NOT PUTTING OIL IN THE ENGINE PRIOR TO START.

DURING CRUISE FLIGHT, PILOTS FELT AN AGGRESSIVE FLUTTER COMING FROM RUDDER. DECLARED AN EMERGENCY AND LANDED WITHOUT FURTHER INCIDENT. MX INSPECTED THE ACFT AND DETERMINED THE RUDDER GEAR TAB HAD FAILED DUE TO A BROKEN CLEVIS BOLT. NOTICED THAT TO RIG THE RUDDER GEAR TAB, HAD TO POSITION ROD END DIFFERENT TO WHAT IT HAD BEEN TO PLACE THE BOLT IN THE VERTICAL POSITION AS DESCRIBED IN THE MM 27-26-00. 1A (2). REPLACED FAILED PART AND RIGGED GEAR TAB IAW AMM 27-26-00. ACFT TEST FLOWN SATIFACTORY AND RETURNED TO SERVICE.

IN FLIGHT PILOT REPORTED ACFT BEGAN TO SHAKE VIOLENTLY. RUDDER PEDALS SHOOK. NO ENGINE ANOMALIES NOTED NO OPEN DOOR INDICATIONS. FLIGHT WAS DISCONTINUED AND ACFT RETURN TO DEPARTURE AIRPORT. UPON INSPECTION THE CLEVIS FORK THAT ATTACHES THE RUDDER GEAR TAB ROD TO THE GEAR TAB MECHANISM WAS FOUND TO BE SHEARED. THE MECHANISM WAS FOUND TO OPERATE SMOOTHLY AND THE TAB WAS FOUND TO MOVE FREELY ON THE HINGE.

FLIGHT CREW WENT TO OPERATE THE WINDSHIELD WIPER SYS FOR GROUND TAXI. THE SYS WAS FOUND TO BE INOPERATIVE AT THE TIME AND AN ACRID BURNING ODOR WAS DETECTED. THE SYS POWER WAS TURNED OFF. THE SYS WAS THEN DEACTIVED AND DEFERRED IAW MEL 30-6. NO FURTHER FLIGHTS FLOWN THAT DAY.

UPON LANDING PILOT WAS INFORMED BY PASSENGER THAT TOUR STATION SEAT 6B HAD LOUD POPPING AND SMOKE WAS OBSERVED. MAINTENANCE INSPECTED AND FOUND NO SMOKE BUT ITEM DID SMELL HOT. TOUR STATION REPLACED. INSPECTED REMOVED TOUR STATION AND FOUND VOLUME CONTROL SWITCH LOOSE AND SHORTED AGAINST METAL REINFORCING PLATE. SOME HOW PASSENGER LOOSENED SWITCH ENOUGH FOR SWITCH TO BACK OUT ENOUGH TO BYPASS THE ANTI-ROTATION PIN AND CONNECTORS TO TOUCH THE METAL BACKING PLATE.

PILOT REPORTED ON LANDING NOSE WHEEL STEERING WAS FULL LEFT DEFLECTION. MAINTENANCE INSPECTED AIRCRAFT AND FOUND NOSE WHEEL CENTERING PIN STUCK IN THE UP POSITION. CAUSE WAS EXCESSIVE PAINT. REMOVED PAINT, OPERATIONALLY CHECKED NOSE WHEEL STEERING AND NO FAULT WAS FOUND. NOTE: THIS AIRCRAFT HAD A COMPLETE PAINTING 17 FLIGHTS PREVIOUS WITH NO DISCREPANCY. A POST PAINT INSPECTION WAS PERFORMED AT THAT TIME, THIS ITEM IS NOT PART OF THAT INSPECTION.

PILOT REPORTED A PASSENGER CONPLAINED OF "SMELL SMOKE". MAINTENANCE FOUND THE AIR CONDITIONER COMPRESSOR MOTOR INOPERATIVE. MOTOR WAS REPLACED. NOTE: AIR CONDITIONER INSTALLED IN CABIN UNDER FLOOR.

ST CROIX - DURING CRUISE EMERGENCY MEASURES EXECUTED. RT ENGINE SHUT DOWN, DECLARED EMERGENCY WITH ATC AIRCRAFT GROUNDED FOR ENGINE CHANGE. ENGINE FAILED DURING CRUISE FLIGHT. PROPELLER FEATHERED. NOTE ENGINE 51369 IS MAINTAINED UNDER GRAND CANYON AIRLINES MAINTENANCE PROGRAM.

ENROUTE, RT ENGINE OIL PRESSURE WAS DROPPING TO 45 PSI. AIR CREW IMMEDIATELY BEGAN TROUBLESHOOTING WITH THE CHECKLISTS. THE OIL PRESSURE LIGHT BEGAN TO FLICKER, AIRCREW SHUTDOWN THE RT ENGINE, DECLARED AND EMERGENCY WITH APPROACH AND LANDED NORMALLY SINGLE ENGINE AT NORTH AIRPORT. UPON RETURN RT ENGINE WAS INSPECTED. RT ENGINE OIL CAP WAS NOT SECURED PROPERLY THUS ALLOWING OIL TO EXIT THE GEARBOX THROUGH THE OIL FILLER NECK. OIL FILTER WAS INSPECTED FOR METAL PARTICLES AND SENT TO ANALYSIS FOR METAL PARTICLES. NEW OIL FILTER WAS INSTALLED, OIL WAS ADDED TO ENGINE, OIL CAP WAS SECURED PROPERLY. AIRCRAFT WAS GROUND RUN AND LEAK CHECKED, OIL PRESSURE INDICATED NORMAL AND AIRCRAFT WAS RETURNED TO SERVICE. (

LT ENGINE OIL PRESSURE STARTED FLUCTUATING. PILOT RETURNED TO AIRPORT. MAINTENANCE CHECKED OIL FILTER AND FOUND METAL IN OIL. ENGINE REMOVED AND SENT TO REPAIR FACILITY. (K)

PILOT REPORTED BURNING SMELL ON LOG BOOK ENTRY. MAINTENANCE ACTIONS FOUND THAT THE AIR CONDITIONING COMPRESSOR MOTOR WAS THE SOURCE OF THE ODOR. A NEW AIR CONDITIONING COMPRESSOR WAS INSTALLED.

DURING CRUISE, ENG EXPERIENCED VIBRATION AND RAPID RISE IN ITT. CREW SHUT DOWN ENGINE. ENG TEAR-DOWN REVEALED STRESS RUPTURE OF HIGH PRESS TURBINE BLADE, P/N 3072712-1. BLADE HRS 3,280.8. SUBMITTER STATED APROX 35 CATASTROPHIC FAILURES HAVE OCCURRED IN 1998. ALLIED SIGNAL HAS ISSUED TFE731 SPECIAL PROGRAM NUMBER FIVE TO ENSURE ALL MAINT ACTION OCCURS AT THEIR CONTROLLED MAINT FACILITIES. SUBMITTER RECOMMENDS FAA ENG ISSUE AD TO LIMIT OPERATING HRS TO 1,500 HRS FOR ALL TFE731-2-1C (FALCON 10/100) AND 2,800 HRS FOR ALL TFE731-2-2B POWERPLANTS WHICH POWERS LEAR 30 SERIES ACFT. REF: W.O. NR GR2-317.

DURING AIRCRAFT SCHEDULED INSPECTION, MAINTENANCE PERSONNEL FOUND LEFT AND RIGHT WING ROOT TO INBOARD BELLCRANK FLAP ROD ASSEMBLIES HEAVILY GROOVED AND SCORED BY ROD GUIDE ROLLERS. THIS IS AN ONGOING CHRONIC PROBLEM ON THIS AIRCRAFT TYPE. GUIDE ROLLERS ARE MADE FROM A HARD MATERIAL THAT DAMAGED THE SOFTER RODS. THESE RODS ARE THE SUBJECT OF AD 80-03-08. MOD 6/1707 HAD PREVIOUSLY BEEN ACCOMPLISHED. (M)

DURING AIRCRAFT SCHEDULED INSPECTION, MAINTENANCE PERSONNEL FOUND LEFT AND RIGHT WING ROOT TO INBOARD BELLCRANK FLAP ROD ASSEMBLIES HEAVILY GROOVED AND SCORED BY ROD GUIDE ROLLERS. THIS IS AN ONGOING CHRONIC PROBLEM ON THIS AIRCRAFT TYPE. GUIDE ROLLERS ARE MADE FROM A HARD MATERIAL THAT DAMAGES THE SOFTER RODS. THESE RODS ARE THE SUBJECT OF AD 80-03-08. MOD 6/1707 HAD PREVIOUSLY BEEN ACCOMPLISHED. (M)

FOUND CRACKS IN LEFT LOWER COWLING SKIN NEAR EXHAUST OPENING. REPAIRED IAW S/B 6/322, INCORPORATED MODIFICATION NR 6/1497. (M)

CREW REPORTED AILERON CONTROL 'STUCK' WHEN ROLLING TO THE RIGHT. AIRCRAFT MADE A SAFE LANDING AT GCN. MAINTENANCE FOUND A HOLLOW RIVET JAMMED IN CONTROL CABLE PULLEY AT FUSELAGE STATION 111.00. CABLE WAS DAMAGED REQUIRING REPLACEMENT. AREA UNDER LEFT CREW SEAT WAS INSPECTED AND CLEANED OF LOOSE DEBRIS. (M)

CREW REPORTED SMELLING SMOKE AND SMELL WENT AWAY AFTER LT DC BUSS WAS SHUT DOWN. MAINTENANCE PERSONNEL REPLACED AIR CONDITIONING COMPRESSOR MOTOR. AIR CONDITIONING SYSTEM IS INSTALLED ON THIS AIRCRAFT UNDER SUPPLEMENTAL TYPE CERTIFICATE NR SA4622SW.

LEFT ENGINE TORQUE PRESSURE DROPPED TO ZERO AFTER SLIGHT POWER REDUCTION, CAME BACK UP TO ABOUT 4 PSI, POWER INCREASED TO 15 PSI. AFTER ANOTHER SLIGHT POWER REDUCTION, TORQUE DROPPED TO ZERO AND OIL PRESSURE DROPPED BELOW 40 PSI. FEATHERED AND SECURED ENGINE. ONCE ON GROUND, MAINTENANCE PERSONNEL RESTARTED ENGINE AND PERFORMED A THOROUGH GROUND RUN, AND COULD NOT DUPLICATE PROBLEM OR FIND ANY DISCREPANCIES. REPLACED THE FUEL CONTROL UNIT AS A PRECAUTIONARY MEASURE BECAUSE NO DISCREPANCIES IN THE ENGINE, ENGINE ACCESSORIES, OR ENGINE SYSTEMS COULD BE FOUND.

DURING PHASE INSPECTION, MAINTENANCE PERSONNEL FOUND ABNORMAL AMOUNT OF METAL IN RIGHT ENGINE MAIN OIL FILTER. UPON FURTHER INVESTIGATION FOUND LARGE STEEL FRAGMENT ON REDUCTION GEARBOX MAGNETIC PLUG. AFTER REMOVAL OF GEARBOX FROM ENGINE, FOUND POWER TURBINE NOT COUPLED TO PROPELLER SHAFT. UPON DISASSEMBLY OF REDUCTION GEARBOX, FOUND POWER TURBINE SHAFT COUPLING BROKEN AT FORWARD RETAINING RING GROOVE AROUND APPROXMATELY 320 DEGREES OF CIRCUMFERENCE.

195 HOURS AFTER INSTALLING OVERHAULED NR 6 TURBINE BEARING, BEARING WAS REMOVED FORM SERVICE DUE TO SPALLED ROLLERS. THIS PROBLEM WAS DISCOVERED DURING A ROUTINE 150-HOUR OIL FILTER ANALYSIS. THE ANALYSIS REVEALED M50 TOOL STEEL PLATELETS, WHICH IS MAIN BEARING MATERIAL. THE REMOVED BEARING WAS RETURNED TO THE OVERHAUL FACILITY.

FLIGHT CREW REPORTED THAT STALL WARNING CAME ON IN-FLIGHT AND REMAINED ON. MAINTENANCE CREW REPLACED INBOARD STALL WARNING SWITCH (LIFT DETECTOR) DUE TO AN INTERNAL SHORT AND AIRCRAFT WAS RELEASED AFTER A SUCCESSFUL TEST FLIGHT. THIS OPERATOR HAS FOUND THIS STALL WARNING SWITCH TO BE SUSCEPTIBLE TO FAILURE ESPECIALLY AFTER PREVIOUS REPAIR. REMOVED SWITCH HAD 570.4 HOURS SINCE PREVIOUS REPAIR BY SAFE FLIGHT. IT IS SUSPECTED THAT MOISTURE CAUSES PREMATURE FAILURES.

STALL WARNING OCCURRED AFER TAKEOFF FROM GEN AIRPORT. CREW PULLED APPLICABLE CIRCUIT BREAKER AND REMAINDER OF FLIGHT FLOWN FLAPS UP. MAINTENANCE REPLACED FAILED INBOARD STALL WARNING SWITCH. THIS AIRCRAFT WAS FLOWN THROUGH MOIST WEATHER ON THIS DATE. THIS SWITCH WAS REPAIRED BY THE MANUFACTURER 82.1 FLIGHT HRS TO THIS FAILURE.

STALL WARNING SOUNDED WHEN FLAPS SELECTED TO 10 DEGREES ON GROUND. MAINTENANCE REPLACED INBOARD STALL WARNING SWITCH. NOTE: AIRCRAFT WAS OPERATED IN MOIST WEATHER ON THIS DATE.

AT 100 KNOTS, AIRSPEED STALL WARNING CAME ON WHEN FLAPS WERE EXTENDED. MAINTENANCE REPLACED OUTBOARD STALL WARING SWITCH. NOTE: AIRCRAFT WAS FLOWN IN MOIST WEATHER ON THIS DATE.