PRO AIRWAYS, LLC

Sanction: $5,000 · case closed 2016-10-07

Part: PITOT LINE — CONTAMINATED · airframe 4,934 hrs · 5,101 cycles

WHILE AT FL40 NOTED YELLOW IAS LIGHT ON BOTH PFD'S. DURING DESCENT NOTED A 60 KT SPLIT (BETWEEN PILOT AND COPILOT PFD). SWITCHED TO ADC2 AND A/S WERE NORMAL. PITCH TRIM ALSO WOULD NOT RESET, FLEW AIRCRAFT IN SBY TRIM. TECHNICIANS AT NASHVILLE, TN, KBNA WERE DISPATCHED TO AIRPORT CODE KJWN, DRAINED WATER FROM LEFT SIDE PITOT/STATIC DRAINS, RESTORED SYSTEM TO NORMAL CONFIGURATION AND ACCOMPLISHED SYSTEM CHECKS, WITH NO DEFECTS NOTED. AIRCRAFT WAS RETURNED TO SERVICE.

Part: FILTER HOUSING — PULLED (ENGINE CASE RT) · airframe 12,149 hrs · 8,339 cycles

DURING A MAINTENANCE GROUND RUN, THE RT ENGINE DEVELOPED A MAJOR OIL LEAK AND WAS IMMEDIATELY SHUT DOWN. TECHNICIANS DISCOVERED THE OIL FILTER BOWL HAD BLOWN OFF. ONE HOLD DOWN STUD HAD COMPLETELY PULLED ITS THREADS OUT OF THE OIL FILTER HOUSING. A SECOND HOLD DOWN STUD HAD PARTIALLY PULLED THREADS. THE BOWL WAS STILL HELD BY ONE STUD, WHICH HAD BEEN BENT WHEN THE OTHER STUDS FAILED. DUE TO THE DESIGN OF THE STUDS AND HOLD DOWN NUTS, NORMAL R&R OF THE OIL FILTER DOES NOT EFFECT THE THREADS THAT FAILED.

Part: ELECTRONIC UNIT — OVERHEATED (ELECTROSTATIC F) · airframe 12,071 hrs · 8,297 cycles

PILOTS NOTICED SMOKE SMELL IN COCKPIT DURING CRUISE FLIGHT, ON TRIP KHYA-KAPF, FOLLOWED BY OBSERVING SMOKE. CONDUCTED EMERGENCY DESCENT AND LANDING AT KSAV. MAINT TECHNICIAN FOUND 2 AC CIRCUIT BREAKERS TRIPPED IN LEFT WINDSCREEN CIRCUIT AND LEFT WINDSCREEN ELECTROSTATIC FILTER UNIT OVERHEAT DAMAGED, DETERMINED THE FILTER WAS THE SOURCE OF THE SMOKE. TECHNICIAN INSPECTED ADJACENT AREA AND EWIS, NO OTHER DAMAGE NOTED. PLACED WINDOW HEAT SYSTEM ON MEL, GROUND RUN OF AIRCRAFT AND SYSTEMS ACCOMPLISHED AND AIRCRAFT RETURNED TO SERVICE.

Part: NONE — NONE (ZONE 600) · airframe 11,542 hrs · 7,898 cycles

AIRCRAFT IMPACTED A DEER ON LANDING AT KPYM. RIGHT TRAILING EDGE FLAP WAS DAMAGED BEYOND REPAIR AND WAS REPLACED.

Part: NONE — NONE · airframe 11,486 hrs · 7,852 cycles

AIRCRAFT WAS ON SHORT FINAL TO KPYM, PLYMOUTH, MA MUNICIPAL AIRPORT, FULLY CONFIGURED FOR LANDING, WHEN PILOTS SAW SMOKE AND HEARD A POPPING SOUND FROM THE COPILOTS INSTRUMENT PANEL NEXT TO THE GEAR HANDLE. A FLAME WAS BRIEFLY OBSERVED BY THE COPILOT IN THE SAME AREA. THE CAUSE OF THIS ISSUE IS CURRENTLY BEING INVESTIGATED BY CRS ZKFR180L AT KPYM. THIS SDR WILL BE REVISED AS TO CAUSE. NOTE-PROPELLER LISTED ABOVE IS #2 ENGINE

Part: HINGE — CORRODED (AILERON TRIM TAB) · airframe 11,353 hrs · 7,767 cycles

RH AILERON SIGNIFICANT CORROSION FOUND AT CENTER TRIM TAB HINGE, AROUND BONDING STRAP ATTACHMENT HOLE, IN AFT SPAR STRUCTURE. TEXTRON ENGINEERING NOTIFIED AND NO REPAIR ALLOWED. NO NEW REPLACEMENT AILERONS AVAILABLE. ACQUIRED AS REMOVED RH AILERON S/N DHB1002 AND SAME IRREPARABLE CORROSION FOUND. ACQUIRED SECOND AS REMOVED RH AILERON S/N DHB1032 AND SAME IRREPARABLE CORROSION FOUND. WE NOW HAVE THREE RH AILERONS FROM THREE DIFFERENT AIRCRAFT WITH UNAIRWORTHY RH AILERONS DUE TO SIGNIFICANT CORROSION OF THE AFT SPAR STRUCTURAL CASTINGS.

Part: ENGINE — FLAMED OUT (LEFT) · airframe 8,814 hrs · 5,913 cycles

DURING CRUISE FLIGHT AT 43,000 FEET LOWER EIED DISPLAY WENT BLANK FOLLOWED BY BAGGAGE FIRE LIGHT AND AURAL WARNING. CREW STARTED DESCENT AND SENT FO TO INSPECT BAGGAGE AREA WITH NO SMOKE OR FIRE FOUND. DURING DESCENT, LEFT ENGINE FLAMED OUT. DECLARED EMERGENCY AND DIVERTED INTO KILM, FOLLOWED RELIGHT CHECKLIST, ENGINE RESTARTED NORMALLY PRIOR TO LANDING. NOTE- AS OF THIS DATE, HONEYWELL HAS NOT MADE A DETERMINATION OF CAUSE. THE ENGINE IS STILL IN THE TEST CELL AT HON.

Part: ENGINE — MAKING METAL (NR 2) · airframe 98,995 hrs · 6,786 cycles

DURING ACCOMPLISHMENT OF ENGINE SHUTDOWN CHECKLIST, FLIGHT CREW NOTED NR 2 ENGINE CHIP INDICATION. TECH REMOVED AND INSPECTED CHIP DETECTOR AND FOUND METAL CONTAMINATION ON BOTH COLLECTION POINTS, FORWARD AND AFT SUMP AREAS. SOAP SAMPLE WAS SUBMITTED FOR ANALYSIS. THIS ENGINE IS A RENTAL ENGINE INSTALLED ON THIS AIRCRAFT 55.6 HOURS AGO. THE PREVIOUS ENGINE WAS REMOVED FOR METAL CONTAMINATION SEE SDR 10-22-2014 AND SDR 11-11-2014 BOTH SUBMITTED FOR SAME AIRCRAFT. NOTE-THIS AIRCRAFT HAS HAD 4 OCCURENCES OF THESE ENGINES MAKING METAL SINCE JULY 2014. THIS PARTICULAR ENGINE P105301 IS 55.6 HOURS SINCE MPI.

Part: BOLT — LOOSE (MAIN WHEEL) · airframe 5,685 hrs · 5,264 cycles

LEFT MAIN TIRE FOUND FLAT AFTER PARKING. TECH REPORTED 5 OUT OF 7 WHEEL HALF THROUGH BOLTS LOOSE CAUSED WHEEL HALF O-RING TO SQUEEZE OUT AND TIRE WENT FLAT. THE TIRE THAT WENT FLAT WAS INSTALLED 11/26/2014 AS AN ASSEMBLY OVERHAULED BY A VENDOR WITH TIRE INSTALLED BY SAME VENDOR DURING OVERHAUL. DOCUMENTATION INCLUDING 8130 TAG FROM VENDOR WILL BE SUBMITTED WITH THIS SDR.

Part: ENGINE — MAKING METAL (RIGHT) · airframe 9,840 hrs · 6,747 cycles

RT ENGINE CHIP INDICATION ON EIED DURING ACFT SHUTDOWN. ENGINE IS 12.5 HOURS OUT OF A NR 3 BEARING REPLACEMENT MAINTENANCE EVENT. ENGINE OIL SOAP WAS PERFORMED AND THE ENGINE REMOVED. THE MAJORITY OF THE DEBRIS WAS DETERMINED TO BE A 300-SERIES STAINLESS STEEL, SPECIFIC TYPE UNDETERMINED. THIS IS HIGHLY UNUSUAL AND UNANTICIPATED. THE RECOMMENDATION AT THIS TIME IS TO REMOVE THE ENGINE FOR FURTHER INVESTIGATION TO DETERMINE SOURCE.

Part: BEARING CAGE — CRACKED (ENGINE) · airframe 9,822 hrs · 6,735 cycles

DURING POWER-UP AND ENGINE START CHECKLIST FLIGHT CREW NOTED NR 2 ENGINE CHIP INDICATION YELLOW ON EIED. MAINTENANCE TECH REMOVED RT ENGINE CHIP DETECTOR AND DISCOVERED METAL CONTAMINATION ON DETECTOR. METAL CHIPS AND OIL FILTER WERE SENT OUT FOR SOAP LAB ANALYSIS; LAB AND MANUFACTURER IDENTIFIED METAL AS BEING FROM NR 3 BEARING AND BEARING SUPPORT. ENGINE WAS DISASSEMBLED AND NR 3 BEARING WAS FOUND WITH A SMALL TO MEDIUM CHIP MISSING FROM THE BEARING CAGE, CHIP WAS RECOVERED FROM SUMP. THE BEARING CAGE WAS ALSO CRACKED. NR 3 BEARING SUPPORT WAS FOUND WITH MISSING PLATING. THE BEARING AND BEARING SUPPORT WERE REPLACED AND NORMAL OPS CHECKS ACCOMPLISHED, ACFT RETURNED TO SERVICE.

Part: ATTACH FITTING — CORRODED (ZONE 300) · airframe 9,084 hrs · 5,483 cycles

DURING SCHEDULED INSPECTION, FOUND CORROSION ON LT SIDE OF VERTICAL TO HORIZONTAL STABILIZER ATTACH FITTING. CORROSION IS INTERGRANULAR, AND IS LOCATED AROUND 12 FASTENER HEADS.

Part: O-RING — LEAKING (WHEEL HALVES) · airframe 8,894 hrs · 5,844 cycles

DURING PREFLIGHT, FLIGHT CREW NOTICED LT INBD TIRE LOOKED LOW. MX DISCOVERED TIRE ALMOST COMPLETELY DEFLATED BUT NOT BLOWN. WHEEL ASSYS ONLY HAD 9 CYCLES SINCE IT WAS O/H. R & R WHEEL/TIRE ASSY. INSPECTED REMOVED WHEEL ASSY AND FOUND AIR LEAKING FROM RIM NEAR VALVE STEM LOCATION (BUT NOT FROM VALVE STEM). MX BELIEVES THAT LEAK IS COMING FROM THE WHEEL HALF SEALING O-RING. THEY ALSO NOTICED THE WHEEL HALF SEALING O-RING WAS A DIFFERNT COLOR (BLUE) THAN NORMAL (BLACK).

Part: O-RING — LEAKING (WHEEL HALVE) · airframe 8,884 hrs · 5,835 cycles

DURING PREFLIGHT, FLIGHT CREW NOTICED LT OTBD TIRE LOOKED LOW. MX DISCOVERED TIRE ALMOST COMPLETELY DEFLATED BUT NOT BLOWN. WHEEL ASSYS ONLY HAD 9 CYCLES SINCE IT WAS O/H. REMOVED AND REPLACED WHEEL/TIRE ASSY. INSPECTED REMOVED WHEEL ASSY AND FOUND AIR LEAKING FROM RIM NEAR VALVE STEM LOCATION (BUT NOT FROM VALVE STEM). MX BELIEVES THAT LEAK IS COMING FROM THE WHEEL HALF SEALING O-RING.

Part: TIRE — FAILED (ZONE 700) · airframe 3,751 hrs · 4,094 cycles

THE LT MAIN TIRE BLEW OUT ON TAKEOFF ROLL. THE RT WHEEL & TIRE ASSY WAS REPLACED. MX CHECKS OF THE ANTI-SKID SYS WERE PERFORMED WITH NO DEFECTS NOTED.

Part: CHECK VALVE — LEAKING (OXYGEN SYSTEM) · airframe 8,748 hrs · 5,704 cycles

OXYGEN SYS NON-RETURN VALVE LEAKING ALLOWING OXYGEN TO FLOW BACKWARDS AND LEAK OUT OF FILLER PORT. THIS WAS A BRAND NEW CHECK VALVE FROM MFG. REMOVED AND REPLACED UNIT.

Part: CHECK VALVE — LEAKING (OXYGEN SYSTEM) · airframe 8,748 hrs · 5,704 cycles

OXYGEN SYSTEM LEAKING: FOUND OXYGEN SYSTEM NON-RETURN VALVE INOP AND ALLOWING OXYGEN TO FLOW BACKWARDS AND LEAKING OUT OF FILLER PORT. REMOVED AND REPLACED NON-RETUEN VALVE AND LEAK CHECKED GOOD. THIS NON RETURN VALVE WAS JUST INSTALLED 9 MONTHS AGO FOR THE SAME ISSUE.

Part: SKIN — DELAMINATED (ZONE 400) · airframe 8,693 hrs · 5,661 cycles

DURING ENGINE CHANGE, CORE COWL SEGMENT FOUND DELAMINATED. MFG HAS A REPAIR FOR THIS PROBLEM BUT UNFORTUNATELY THE EXTENT OF DAMAGE TO THIS CORE COWL IS BEYOND ALL LIMITS OF REPAIR. THE REPAIR IS USUALLY FOR A SMALL AMOUNT OF LIFTING AT THE CORNERS OF THE BONDMENT. MFG INFORMED THAT IT DOES NOT HOLD PMA FOR THIS PROGRAM SO THE NEW PART WILL NEED TO BE PURCHASED THROUGH HBP&D. RDO INFORMED THAT THEY ARE NOT ABLE TO PRODUCE A REPAIR FOR THIS ISSUE. THIS IS DUE TO THE ACOUSTIC PROPERTIES OF THE COWL. THE COWL MUST BE REPLACED WITH NEW OR SERVICEABLE PART. R & R CORE COWL SEGMENT.

Part: ACTUATOR — LEAKING (ZONE 400) · airframe 709 hrs · 436 cycles

RT ENGINE, INBD THRUST REVERSER ACTUATOR LEAKING. MM SPECIFICALLY STATES THERE ARE NO ALLOWABLE LEAKAGE FOR COMPONENTS, FILTERS, PRESSURE SWITCHES, TRANSDUCERS, VALVES OR TUBING UNLESS SPECIFICALLY MENTIONED AND TO CONTACT MFG CUSTOMER SUPPORT WHEN ANY MX ON THE THRUST REVERSER SYS IS PERFORMED, INCLUDING PART REPLACEMENT, ADJUSTMENT OR REPAIR. OUR TECH REP AS CONTACTED AND WE REMOVED THE ACTUATOR AND INSTALLED A NEW UNIT IAW AMM 78-30-03. OPS AND LEAK CHECKED GOOD.

Part: ACTUATOR — LEAKING (THRUST REVERSER) · airframe 709 hrs · 436 cycles

LT ENGINE, INBD THRUST REVERSER ACTUATOR LEAKING. MM SPECIFICALLY STATES THERE ARE NO ALLOWABLE LEAKAGE FOR COMPONENTS, FILTERS, PRESSURE SWITCHES, TRANSDUCERS, VALVES OR TUBING UNLESS SPECIFICALLY MENTIONED AND TO CONTACT MFG CUSTOMER SUPPORT WHEN ANY MX ON THE THRUST REVERSER SYSTEM IS PERFORMED, INCLUDING PART REPLACEMENT, ADJUSTMENT OR REPAIR. OUR TECH REP AS CONTACTED AND WE REMOVED THE ACTUATOR AND INSTALLED A NEW UNIT IAW AMM 78-30-03. OPS AND LEAK CHECKED GOOD.

Part: FRAME — CRACKED (DOOR STEP) · airframe 3,588 hrs · 3,230 cycles

FWD STAIR FRAME CRACKED. R & R FWD STAIR FRAME AND INSTALLED STAIR IMPROVEMENT KIT 128-4045-0003.

Part: FRAME — CRACKED (DOOR STEP) · airframe 3,588 hrs · 3,230 cycles

AFT STAIR FRAME CRACKED. R & R FWD STAIR FRAME AND INSTALLED STAIR IMPROVEMENT KIT 128-4045-0003.

Part: CHECK VALVE — FAULTY (POTABLE WATER) · airframe 430 hrs

POTABLE WATER IN LAV HAS LOW PRESSURE AND PUMP CONTINUOUSLY CYCLES. R & R DRAIN CHECK VALVE. OPS CHECKED GOOD. INSPECTED CHECK VALVE ON BENCH AND FOUND VALVE NOT COMPLETELY CLOSING AND REQUIRING EXCESSIVE PRESSURE TO CLOSE AT ALL.

Part: WIRE — BROKEN (LIGHT) · airframe 430 hrs

AFT BAY MX LIGHT WILL NOT STAY ON. FOUND MULTIPLE BROKEN WIRES AT AFT STEP FAIRING, SWITCH TO SPLICE, ON LT AND RT SIDE OF ACCESS DOOR. REPAIRED AFFECTED WIRES. OPS CHECKED GOOD.

Part: PROCESSOR — FAULTED (MAU 2) · airframe 430 hrs

WITH ONLY APU RUNNING, MAU 2B FAULTED RESULTING IN THE APU SHUTING DOWN. PILOT RESTARTED APU AND FAULT DID NOT RETURN. MX COULD NOT DUPLICATE PROBLEM. FAULT HISTORY DOWNLOADED, CHANGE THE MAU 2 NIC 2 MODULE ASSY WITH PROCESSOR. OPS CHECKED GOOD.

Part: CONTROLLER — FAULTY (CABIN TEMP) · airframe 8,595 hrs · 5,605 cycles

CABIN TEMPERTURE UNCONTROLLABLE IN AUTO MODE. FOUND CABIN TEMPERTURE CONTROLLER NOT PROVIDING ANY OUTPUT VOLTAGE. CONTROLLLER GIVES MOMENTARY PULSES ONLY VISIBLE USING A TEST LAMP WHICH CAUSES TEMP CONTROL VALVE TO "CLICK" BUT NOT ENOUGH TO MOVE VALVE. R & R CABIN TEMP CONTROLLER. OPS CHECKED GOOD.

Part: FAN — INOPERATIVE (A/C HEAT XCHANGR) · airframe 684 hrs · 420 cycles

DURING POSTFLIGHT, FOUND BOTH AFT BAY HEAT EXCHANGER FANS INOP. R & R BOTH HEAT EXCHANGERS FANS. OPS CHECKS GOOD. MX RECOMMENDS OTHER OPERATORS CHECK FOR OPS AS THERE IS NO COCKPIT INDICATION WHEN THESE FANS FAIL AND THEY ARE FOR HEAT PROTECTION FOR THE COMPOSITE REAR PRESSURE BULKHEAD STRUCTURE.

Part: CONNECTOR — DISCONNECTED (BLOWER) · airframe 684 hrs · 420 cycles

WHILE CHANGING LT AFT BAY HEAT EXCHANGER FOUND CB PANEL 3, PLUG P1634D, PIN: M FOR WIRE A201-W01-16 CAPPED AND TIED BACK CAUSING LT AFT BAY BLOWER TO BE INOPERATIVE. MECHANIC BELIEVES THIS TO BE DONE DURING ACFT PRODUCTION OR AT BLOCK 20 UPGRADE. MECHANIC RECOMMENDS OTHER OPERATORS CHECK FOR OPERATION AS THERE IS NO COCKPIT INDICATION WHEN THESE FANS ARE INOP AND THEY ARE FOR HEAT PROTECTION FOR THE COMPOSITE REAR PRESSURE BULKHEAD STRUCTURE. SEE CONTROL ZKFR113188A FOR OTHER SN.

Part: FAN — INOPERATIVE (A/C HEAT XCHANGR) · airframe 684 hrs · 420 cycles

DURING POSTFLIGHT FOUND BOTH AFT BAY HEAT EXCHANGER FANS INOPERATIVE. R & R BOTH HEAT EXCHANGERS FANS. OPS CHECKED GOOD.

Part: SHUTOFF VALVE — FAILED (LT A/C PACK) · airframe 684 hrs · 420 cycles

LT PACK FAILED IN FLIGHT WHEN THROTTLES PULLED TO IDLE. R & R LT PACK PRESSURE RELIEF SHUTOFF VALVE (PRSOV). SYS OPS CHECKS GOOD.

Part: CIRCUIT CARD — FAILED (CMC) · airframe 605 hrs · 389 cycles

FOUND CMC CARD TO BE FAILED. R & R CMC MODULE ASSY (CARD). OPS CHECKS GOOD.

Part: TIRE — SEPARATED (ZONE 700) · airframe 4,647 hrs · 4,170 cycles

FLIGHT CREW NOTED ABNORMAL BRAKING AND CONTROL ON LANDING, ACFT CLEARED RUNWAY AND STOPPED ON RAMP WITH NO INCIDENT. FOUND LT MAIN TIRE FLAT WITH TREAD MISSING, NO OTHER ACFT DAMAGE NOTED. MX INSPECTED ACFT, AND REPLACED TIRE AND WHEEL ASSY. MX FOUND TREAD CAP SEPARATED FROM TIRE, AND FOUND THROUGH BOLTS IN WHEEL HALVES FINGER TIGHT. MX DETERMINED THAT WHEEL THROUGH BOLTS BACKED OFF, CAUSING TIRE FAILURE. WHEEL ASSY O/H BY VENDOR 1.3 HOURS SINCE O/H.

Part: PUMP — LEAKING (ZONE 300) · airframe 592 hrs · 377 cycles

ERS PUMP LEAKING. FOUND LEAKING FROM OVERBOARD DRAIN LINE. R & R ERS PUMP ASSY.

Part: STARTER GEN — FAILED (NR 2 ENGINE) · airframe 8,400 hrs · 5,440 cycles

ACFT EXPERIENCED MODERATE VIBRATION IN CRUISE, FLIGHT CREW FELT VIBRATION WAS FROM NR 2 ENGINE, FOLLOWED SHORTLY AFTER WITH GEN 2 FAIL INDICATION, CREW SHUTDOWN NR 2 ENGINE, FLIGHT DIVERTED FOR NON-EVENTFUL SINGLE ENGINE LANDING. MX REMOVED NR 2 ENGINE STARTER GEN UNIT, FOUND UNIT FAILED, WITH INTERNAL COOLING FAN ASSY CONTACTING GENERATOR SHROUD. STARTER GEN UNIT HAD 305.1 HOURS SINCE O/H, THIS UNIT TBO IS 1000 HOURS.

Part: STARTER GEN — DESTROYED (ZONE 400) · airframe 8,314 hrs · 5,393 cycles

DURING CRUISE FLIGHT, EXPERIENCED VIBRATION, BELIEVED TO BE FROM ENGINE AREA. VIBRATION INCREASED, BUT DID NOT SHOW ON EVM INDICATOR, FOLLOWED BY GEN 1 FAIL INDICATION, WITH BUS TIE CLOSED IN FLIGHT. ACFT MADE UNSCHEDULED LANDING. MX FOUND NR1 STARTER GEN FAILED, COOLING FAN ON GEN SHATTERED, SHAFT SHEARED, MANY BROKEN PIECES OF UNIT IN ENGINE COWLING.