What was found
DURING FLIGHT, PILOT REPORTED FUEL FLOW DISCREPANCY AND ENGINE ROUGHNESS AND RETUNRED TO BASE FOR A PRECAUTIONARY, ALBEIT IF VERY STRESSFUL, LANDING. UPON INSPECTION OF THE FUEL FLOW SENSOR ( PART OF THE JPI 930 ENGINE INSTRUMENTAION - STC SA01435SA ) IT WAS DETERMINED THAT THE FLOW METER PINS ( A FLOSCAN 201 UNIT PROVIDED FROM JPI ) HAD BEEN INCORRECTLY TERMINATED. THE MALE PINS HAD BEEN CRIMPED ON WIRES THAT WERE STRIPPED TO LONG. THESE UNITS WERE SHIPPED FROM JPI PINNED AND INSIDE A TERMINAL BLOCK, MAKING VISUAL INSPECTION DIFFICULT WITHOUT PIN REMOVAL. ADDITIONALY, WHO UNPINS ITEMS SHIPPED FROM THE "MANUFACTURER" JUST TO CHECK- WHILE THE PART OF THE PIN THAT WAS SUPPOSED TO BE ON THE BARE WIRE CONDUCTOR WAS CRIMPED CORRECTLY, THE SECOND CRIMP WHICH IS SUPPOSED TO BE ON THE INSULATION ( STRAIN RELIEF ) WAS ALSO CRIMPED ON THE CONDUCTOR, WHICH IS INCORRECT. THE SECOND CRIMP WAS ALSO LOOSE, AS THE THE INSULATION WHICH WOULD NOMALLY BE A PART OF THE OVERALL THICKNESS, WAS ABSCENT. THIS LOOSE CRIMP, AND ABSCENT STRAIN RELIEF , ALLOWED THE WIRES TO FLEX AND EVENTAULLY BREAK. WHILE ONLY ONE OF THE THREE WIRES BROKE, THE OTHERS HAD LESS THAN 25% OF THIER STRANDS INTACT. SUBSEQUENT INSECTIONS OF OTHER AC IN OUR FLEET, WITH SIMILAR FLOSCAN UNITS FROM THE SAME STC, REVEALED 2 OTHER UNITS WITH THE SAME ISSUE. IN TOTAL, WE FOUND 3 FLOSCAN 201 UNITS ( SN'S 218375, 223453, AND 230659 ) ALL WITH THE SAME MISCRIMPED PINS. WE HAD AT LEAST ONE ADDITIONAL UNIT THAT WAS REMOVED PREVIOUSLY "INOP" THAT WE COULDNT VERIFY AS IT WAS DISCARDED.