ABERDEEN FLYING SERVICE INC

Operated by ABERDEEN FLYING SERVICE (per NTSB report)

Operated by ABERDEEN FLYING SERVICE (per NTSB report)

DURING TAKEOFF ROLL, THE RT ENG WOULD NOT MAKE FULL POWER. THE PILOT CANCELLED THE TAKEOFF & RETURNED TO THE SHOP. THE ACFT NEVER LEFT THE GND. MX WAS NOTIFIED & TROUBLE SHOT THE ISSUE. THE RT ENG WASTE GATE WAS LEAKING OIL OUT OF THE CASE AT THE SEAL, THIS WOULD HAVE CAUSED THE TURBOCHARGER TO NOT ENGAGE PROPERLY. THE WASTE GATE WAS REPLACED WITH AN OVERHAULED UNIT. A GND RUN WAS PERFORMED & A SECOND ISSUE WAS FOUND. THE ENG DRIVE FUEL PUMP WAS PUMPING ERRATIC AT HIGH POWER SETTINGS. THE FUEL PUMP WAS REPLACED WITH AN OVERHAULED UNIT. WE RIGGED THE FUEL PUMP TO THE ENG & PERFORMED SEVERAL GND RUNS AT VARIOUS POWER SETTINGS. ALL SYS CHECKED GOOD ON THE GND. A FLIGHT CHECK WAS PERFORMED WITH A PILOT. THE ENG RAN AS DESIGNED IN FLIGHT. NO FURTHER ISSUES NOTED.

DURING TAKEOFF ROLL THE RIGHT ENGINE WOULD NOT MAKE FULL POWER. THE PILOT CANCELLED THE TAKEOFF AND RETURNED TO THE SHOP. THE AIRCRAFT NEVER LEFT THE GROUND. MAINTENANCE WAS NOTIFIED AND TROUBLESHOOT THE ISSUE. MAINTENANCE FOUND THE RIGHT ENGINE WASTE GATE WAS LEAKING OIL OUT OF THE CASE AT THE SEAL, THIS WOULD HAVE CAUSED THE TURBOCHARGER TO NOT ENGAGE PROPERLY. THE WASTE GATE WAS REPLACED WITH AN OVERHAULED UNIT. A GROUND RUN WAS PERFORMED AND A SECOND ISSUE WAS FOUND. THE ENGINE DRIVE FUEL PUMP WAS PUMPING ERRATIC AT HIGH POWER SETTINGS. THE FUEL PUMP WAS REPLACED WITH AN OVERHAULED UNIT. WE RIGGED THE FUEL PUMP TO THE ENGINE AND PERFORMED SEVERAL GROUND RUNS AT VARIOUS POWER SETTINGS. ALL SYSTEMS CHECKED GOOD ON THE GROUND. A FLIGHT CHECK WAS PERFORMED WITH A PILOT. THE ENGINE RAN AS DESIGNED IN FLIGHT. NO FURTHER ISSUES NOTED.

THE NAVIGATION LIGHTS CB FAILED. THE BREAKER FAILED IN SUCH A WAY THAT THE BREAKER REMAINED IN THE ON POSITION & COULD NOT BE TURNED OFF. THE CLIP INSIDE THE BREAKER HAD BROKEN FREE & THEN FALLEN DOWN INSIDE THE BREAKER WHERE IT HAD WEDGED ITSELF BETWEEN THE TWO CONTACTS. THE RESULT WAS THAT THE PILOT COULD NOT SHUT OFF THE FLOW OF POWER. SINCE THE POWER COULD NOT BE TURNED OFF, THE SHORT IN THE WIRING REMAINED ON & THEN STARTED TO MELT OTHER WIRING & CAUSING SEVERAL SYSTEMS TO FAIL & THE PILOT REPORTED SMELLING SMOKE. THE PILOT LANDED & WHEN MX INSPECTED THE WIRING THEY FOUND A LARGE PORTION OF THE SYS IN THE ACFT WIRING TO BE MELTED & OR EITHER FUSED OR DISCONNECTED.

WE LOCATED A CRACK OF THE LOWER CABIN DOOR AFT PART OF THE DOOR FRAME NEAR THE DOOR HINGE. LOCATED AT STATION 270. THE CRACK IS ROUGHLY 2 INCHES IN LENGTH ALONG THE CTR LINE OF THE RADIUS OF THE FRAME BEND. THESE CRACKS APPEAR ON THE DOOR FRAMES DUE TO HOW PEOPLE STEP WHEN ENTERING OR EXITING THE ACFT. MOST PEOPLE TEND TO USE THEIR RT FOOT FIRST WHEN ENTERING THE ACFT WHICH ALL THEIR WEIGHT ON THE AFT PART OF THE DOOR & HINGE AREA. OVER TIME THE FRAME WILL CRACK & THE CRACK WILL ENLARGE AS THE ACFT IS USED. IT WOULD BE A GOOD IDEA IF A TIMED INSPECTION WAS GIVEN TO CHECK THESE FRAMES AT EACH ANNUAL.

THE ACFT HAD TOTAL ELECTRICAL FAILURE DURING FLIGHT, DUE TO BOTH CHARGING SYSTEMS FAILING TOGETHER. RT ALTERNATOR FAILED DURING CRUISE, SHORTLY AFTER LT ALTERNATOR FAILED DUE TO A FAILED DRIVE CLUTCH. THE RT ALTERNATOR APPEARED TO HAVE AN INTERNAL SHORT THAT CAUSED A SUDDEN POWER SPIKE TO GO THRU THE WIRING TO THE REGULATOR. THE SUDDEN SPIKE CAUSED BOTH REGULATORS TO FAIL ALSO. THE ACFT DIVERTED FROM IT'S PLANNED AIRPORT FOR LANDING TO ANOTHER AIRPORT DUE TO WEATHER AND NO ELECTRICAL POWER. THE PILOT USED THE EMERGENCY GEAR BLOWDOWN SYS TO PUT THE GEAR DOWN AND LOCKED AND PROCEED TO LAND THE ACFT SAFELY AT THE ALTERNATE AIRPORT WITHOUT ANY ADDITIONAL ISSUES. THE MECHANIC ON STATION REMOVED THE ALTERNATOR AND REPORTED THAT IT HAD A BURNED SMELL. HE REPLACED THE ALTERNATOR, DRIVE CLUTCH, BATTERY AND BOTH REGULATORS. INSPECTED THE WIRING GOING INTO THE ACFT FOR ANY SIGNS OF DAMAGE, NONE WAS FOUND. PROCEED TO PERFORM A GROUND RUN UP AND SYSTEM CHECK. ALL SYSTEMS OPERATED AS DESIGNED AND WITHIN LIMITS.

DURING FLIGHT, THE LT ENGINE ALTERNATOR STOPPED PRODUCING POWER DUE TO THE DRIVE CLUTCH SLIPPING. AFTER LANDING, REMOVED ALTERNATOR AND CHECKED THE DRIVE CLUTCH. COULD TURN THE CLUTCH BY HAND WITH SOME FORCE. REPLACED THE CLUTCH, REGULATOR AND ALTERNATOR. PERFORMED AND GROUND RUN AND THE CHARGING SYSTEM WORKED AS DESIGNED. REGULATOR REPLACED DUE TO THE RT ENGINE ALTERNATOR HAVING AND INTERNAL SHORT WHICH CAUSED A POWER SPIKE TO TRANSMIT THRU THE WIRING TO THE REGULATOR. NO OPERATIONAL PROBLEMS NOTED BEFORE FAILURE.

DURING INSPECTION WE FOUND THE NR 3 CYLINDER TO HAVE A CRACK & WAS LEAKING FUEL DOWN ON TO THE INTAKE PIPE. PROCEEDED TO INSPECT THE CYLINDER & IT WAS FOUND TO HAVE A CRACK. THE CRACK WAS BETWEEN THE 1ST & 2ND LARGE COOLING FIN BEHIND THE FUEL INJECTOR & DOWN ALONG THE SIDE AREA. THE CRACK APPEARED TO BE NEAR THE AREA OF THE VLV SEAT. REPLACEMENT CYLINDER SENT IN TO US FOR FULL WARRANTY. A BORESCOPE INSPECTION ON A FEW CYLINDERS, CHECKED THE EGT & CHT PROBE. AFTER ALL INSPECTIONS & TEST FOUND NOTHING WRONG IN THE CYLINDERS OR OUR OPERATION OF THE ACFT.

DURING INSPECTION, FOUND CYLINDER CRACKED.

DURING INSPECTION FOUND CYLINDER CRACKED.

CRACKED ENGINE CYLINDER.

CRACKED ENGINE CYLINDER.

CRACKED ENGINE CYLINDER.

CYLINDER ENGINE CRACKED.

CRACKED ENGINE CYLINDER.

CRACKED ENGINE CYLINDER.

CRACKED ENGINE CYLINDER.

CRACKED ENGINE CYLINDER.

DURING INSPECTION, FOUND CYLINDER CRACKED.

DURING INSPECTION, FOUND CYLINDER CRACKED.

DURING INSPECTION, FOUND CYLINDER CRACKED.

DURING INSPECTION, FOUND CYLINDER CRACKED.

CRACKED ENGINE CYLINDER.

CRACKED ENGINE CYLINDER.

CRACKED ENGINE CYLINDER.

DURING INSPECTION, FOUND CYLINDER CRACKED.

DURING INSPECTION, FOUND CYLINDER CRACKED.

DURING INSPECTION, FOUND CYLINDER CRACKED.

DURING INSPECTION, FOUND CYLINDER CRACKED.

CRACKED ENGINE CYLINDER.

CRACKED ENGINE CYLINDER.

DURING INSPECTION, FOUND CYLINDER CRACKED.

DURING INSPECTION, FOUND CYLINDER CRACKED.

DURING INSPECTION, FOUND CYLINDER CRACKED.

DURING INSPECTION, FOUND CYLINDER CRACKED.

DURING AND INSPECTION, FOUND CYLINDER CRACKED.

DURING AN INSPECTION, FOUND CYLINDER CRACKED.

DURING INSPECTION, FOUND CYLINDER CRACKED.

DURING AN INSPECTION, FOUND CYLINDER CRACKED.

CRACKED ENGINE CYLINDER.

CRACKED ENGINE CYLINDER.

CRACKED CYLINDERS.

DURING AN INSPECTION WE FOUND SEVERAL ECI CYLINDER TO BE CRACKED AT EITHER THE SPARK PLUG PORT OR BETWEEN THE FINS.

DURING AN INSPECTION WE FOUND SEVERAL ECI CYLINDERS CRACKED EITHER BY THE FUEL INJECTOR PORT OR BETWEEN THE FIRST SET OF FINS.

FOUND BULKHEAD AT BS 295.17 CRACKED FROM UPPER LT AND RT LIGHTNING HOLE THROUGH INBD FLANGE. IN ADDITION A .2500" CRACK WAS FOUND PROTRUDING INBD FROM STRINGER RELIEF JUST ABOVE TOP LT LIGHTNING HOLE.

ACFT DEPARTED ON A IFR FLIGHT PLAN AT 13:17Z WITH 5 PASSENGERS ONBOARD. JUST AFTER DEPARTURE, AT APPROX 500 FEET, THE CAPTAIN SMELLED AND NOTICED SMOKE COMING FROM THE THROTTLE QUADRANT AREA, SPECIFICALLY THE INTERIOR LIGHT CONTROL PANEL. HE IMMEDIATELY NOTIFIED THE CONTROL TOWER AND LANDED THE ACFT. DISPATCHED BY THE DIRECTOR OF MAINTENANCE TO INVESTIGATE THE PROBLEM AND THEY CONFIRMED THAT IN FACT THE INSTRUMENT LIGHT ON-OFF SWITCH IN THE LIGHTING CONTROL PANEL HAD FAILED.

THE AIRCRAFT WAS IN CRUISE POWER CONFIGURATION. NR 5 CYLINDER BARREL ON RT ENGINE CRACKED AND SEPARATED APPROXIMATELY 3 INCHES FROM MOUNTING BASE IN THE BARREL AREA. DAMAGE WAS DONE TO THE PISTON AND CONNECTING ROD AT THE TIME OF SEPARATION. CAUSE IS UNKNOWN. (K)

THIS FIRE BOTTLE HAS 1 YEAR ON IT AND THE PRESSURE HAS DROPED TO 20 PSI. THIS IS THE SECOND FIRE BOTTLE THAT DID NOT MAKE IT TO 5 YEARS. OVERHAULED BY KELLY AEROSPACE. (QUALITY OF WORKMANSHIP AND OR PARTS)? THIS NEVER HAS BEEN A PROBLEM.

LOWER DOOR FRAME CRACKING BY THE REAR HINGE.

UPON DESCENT, A HEAVY LOAD WAS APPLIED TO THE ELECTRICAL SYSTEM CAUSING THE MASTER RELAY TO FAIL. SUBSEQUENT PARTIAL POWER LOSS TO THE CABIN RESULTED. THIS REPORT IS FOR C/W FAR 135.415 AND AFS OPS MANUAL 5.9.

DURING ANNUAL INSPECTION, FOUND EXCESSIVE SIDE-PLAY IN ELEVATOR BELLCRANK ASSY, FURTHER INVESTIGATION FOUND BEARING AT FAULT. REMOVAL OF BELLCRANK REVEALED BENT BOLT WHICH ADDED DIFFICULTY IN REMOVING ASSY. SUSPECT CAUSE COULD BE NOT USING ELEVATOR CONTROL LOCK IN WINDY CONDITIONS.