N784XJ

ATA 2750

Part: FLAP SYSTEM — WARNING MESSAGE · airframe 19,847 hrs · 10,912 cycles

CREW REPORTS FLAP FAIL CAS MESSAGE POSTED. POWERED UP AIRCRAFT AND DID NOT HAVE ACTIVE FLAP FAIL CAS MESSAGE BUT FOUND MOTOR FAULT, COMMAND ERROR, GROUND FAULT, NO COMMAND, AND INTERNAL FAULT AT FLAP CONTROLLER BOX. RESET FLAP FAULTS, CYCLED FLAPS / SLATS SEVERAL TIMES AND FAULTS DID NOT RETURN. ALSO PERFORMED VISUAL INSPECTION OF FLAPS, ROLLERS TRACKS, ACTUATORS AND FLEX SHAFTS WITH NO DISCREPANCIES NOTED.

ATA 2750

Part: FLAP SYSTEM — FAILED · airframe 18,509 hrs · 10,353 cycles

ON APPROACH INTO JAC THE AIRCRAFT HAD A FLAP FAILURE WHICH WOULD NOT RESET. DUE TO WEATHER CONDITIONS THE AIRCRAFT REQUIRED A LONGER RUNWAY AND THE CREW ELECTED TO DIVERT TO ANOTHER AIRFIELD. AN EMERGENCY WAS DECLARED AND THE AIRCRAFT LANDED WITHOUT INCIDENT. THE AIRCRAFT IS CURRENTLY AT A MAINTENANCE FACILITY AT THE TIME OF THIS REPORT. OPEN

ATA 2750

Part: NONE — FAILED (ZONE 100) · airframe 18,509 hrs · 10,353 cycles

* SUPPLEMENTAL INFORMATION TO THE INITIAL REPORT SUBMITTED ON CONTROL NUMBER AWKA202201050001 FILES ON DECEMBER 28, 2021 * TECHNICIANS INSPECTED THE FLAP SYSTEM AND FOUND THE INBOARD, LEFT FLAP PANEL TIGHT AND THE FLAP POWER DRIVE UNIT FAULTY. THE OUTBOARD FLAP ACTUATOR OF THE L/H FLAP PANEL WAS ADJUSTED AND THE FLAP PDU WAS REPLACED WITH AN OVERHAULED UNIT. OPERATIONAL CHECKS WERE COMPLETED SATISFACTORILY AND THE AIRCRAFT RETURNED TO SERVICE.

ATA 2797

Part: GROUND STUD — DIRTY (TE FLAPS) · airframe 16,640 hrs · 9,499 cycles

DURING RETURN TO LNK AND WHILE CONDUCTING A MX CONFIDENCE FLIGHT FOR FLAP ISSUE, FLIGHT CREW RECEIVED AN AMBER FLAP FAIL CAS MESSAGE. CREW RAN THE APPROPRIATE CHECKLIST AND THEN DECLARED AN EMERGENCY. SEVERAL MINUTES FOLLOWING, CREW WAS ABLE TO LOWER THE FLAPS TO 15 DEGREES AND PROCEEDED TO LAND WITH NO FURTHER ISSUES. MAINTENANCE ACCOMPLISHED TROUBLESHOOTING OF THE FLAP SYSTEM, CLEANED MULTIPLE GROUND TERMINALS AND REPLACED THE FLAP SOFT START MODULE (P/N: 6238405-34 S/N: 0858); FUNCTIONAL TEST WAS NORMAL. A SUCCESSFUL MX CONFIDENCE FLIGHT WAS PERFORMED AND THE AIRCRAFT RETURNED TO SERVICE.

ATA 2750

Part: CURRENT LIMITER — FAILED (FALP SYSTEM) · airframe 15,964 hrs · 9,171 cycles

WHILE CLIMBING OUT, THE FLAP SYSTEM FAILED AT 0. THE FLIGHT CREW ELECTED TO RETURN TO THE DEPARTURE FIELD. THE AIRCRAFT LANDED WITHOUT INCIDENT. TECHNICIANS INSPECTED THE AIRPLANE AND DETERMINED THE FLAP CONTROLLER TO BE FAULTY (P/N 6718328-1). THE UNIT WAS REPLACED AND A MAINTENANCE FLIGHT WAS PERFORMED TO VERIFY PROPER OPERATION. DURING THE MAINTENANCE FLIGHT, THE AIRCRAFT EXPERIENCED ANOTHER FLAP FAILURE. FURTHER TROUBLESHOOTING REVEALED A FAULTY CURRENT LIMITER (P/N ANL150)AND CIRCUIT BREAKER (S2899L0.5). BOTH COMPONENTS WERE REPLACED AND OPERATIONAL CHECKS COMPLETED. ANOTHER MAINTENANCE FLIGHT HAS BEEN SCHEDULED TO VERIFY PROPER OPERATION OF THE FLAP SYSTEM.

ATA 2750

Part: CONTROLLER — FAILED (TE FLAPS) · airframe 15,962 hrs · 9,170 cycles

WHILE IN CRUISE FLIGHT AT FL470, THE FLIGHT CREW RECEIVED AN AMBER FLAPS FAIL CAS MESSAGE. FOLLOWING THE EMERGENCY CHECK LIST, THE CREW ATTEMPTED A FLAP RESET, BUT, THE CAS MESSAGE IMMEDIATELY RE-POSTED. DUE TO RUNWAY LENGTH AT DESTINATION AIRPORT, THE DECISION WAS MADE TO DIVERT INTO GSO. TECHNICIANS INSPECTED THE AIRPLANE AND DETERMINED THE SOFT START RELAY (P/N 6236405-34 AND THE FLAP POWER DRIVE UNIT (P/N MP50G4) WERE FAULTY. THE COMPONENTS WERE REPLACED AND THE AIRCRAFT SUBSEQUENTLY RETURNED TO SERVICE. DURING THE MAINTENANCE CHECK FLIGHT, THE CREW EXPERIENCED A REPEAT FLAP FAILURE. THE AIRCRAFT RETURNED TO THE DEPARTURE FIELD FOR MAINTENANCE. IT WAS DETERMINED THE FLAP CONTROLLER WAS FAULTY (P/N 6718328-1) AND THE AIRCRAFT RETURNED TO SERVICE. CURRENTLY, NO FURTHER ISSUES HAVE BEEN NOTED.

ATA 2750

Part: GEARBOX — FAILED (TE FLAP) · airframe 15,878 hrs · 9,128 cycles

WHILE ON APPROACH INTO KEGE, RECEIVED A FLAP FAIL CAS MESSAGE. RAN THE FLAP FAILURE CHECKLIST AND INFORMED APPROACH CONTROL OF THEIR SITUATION AND REQUESTED TO BREAK OFF THE APPROACH TO KEGE. FOLLOWING AN UNSUCCESSFUL ATTEMPT TO RESET THE FLAPS, CREW DECIDED ON KDEN AS THE LANDING FIELD SINCE IT PROVIDED A 16,000FT RUNWAY IN CASE THE SLATS WOULD NOT EXTEND, AND THEY WOULD LAND WITH 2300LBS FUEL REMAINING. DECLARED AN EMERGENCY IN REGARDS TO THE FLAP ISSUE AND LOW FUEL SITUATION, THEY DID NOT CALL MINIMUM FUEL, HOWEVER THEY DID INFORM ATC THAT THEY COULD BE IN A MINIMUM FUEL SITUATION IF THEY DID NOT GET PRIORITY HANDLING. THEY WERE CLEARED DIRECT TO KDEN WHERE THEY LANDED WITHOUT INCIDENT. MX FOUND TWO FAULTY FLAP GEARBOXES WHEN FROZEN (LT NR 1 P/N: C144824-1 S/N: 2201 & RT NR 2 P/N: C144824-1 S/N: 1567). BOTH GEARBOXES WERE REPLACED WITH OVERHAULED AND INSPECTED/TESTED UNITS. FLAP SYSTEM RIG AND OPERATIONAL CHECKS WERE NORMAL. THE AIRCRAFT WAS RELEASED BACK INTO SERVICE.

ATA 2750

Part: GEARBOX — FAILED (TE FLAP) · airframe 15,878 hrs · 9,128 cycles

WHILE ON APPROACH INTO KEGE, RECEIVED A FLAP FAIL CAS MESSAGE. RAN THE FLAP FAILURE CHECKLIST AND INFORMED APPROACH CONTROL OF THEIR SITUATION AND REQUESTED TO BREAK OFF THE APPROACH TO KEGE. FOLLOWING AN UNSUCCESSFUL ATTEMPT TO RESET THE FLAPS, CREW DECIDED ON KDEN AS THE LANDING FIELD SINCE IT PROVIDED A 16,000FT RUNWAY IN CASE THE SLATS WOULD NOT EXTEND, AND THEY WOULD LAND WITH 2300LBS FUEL REMAINING. DECLARED AN EMERGENCY IN REGARDS TO THE FLAP ISSUE AND LOW FUEL SITUATION, THEY DID NOT CALL MINIMUM FUEL, HOWEVER THEY DID INFORM ATC THAT THEY COULD BE IN A MINIMUM FUEL SITUATION IF THEY DID NOT GET PRIORITY HANDLING. THEY WERE CLEARED DIRECT TO KDEN WHERE THEY LANDED WITHOUT INCIDENT. MX FOUND TWO FAULTY FLAP GEARBOXES WHEN FROZEN (LT NR 1 P/N: C144824-1 S/N: 2201 & RT NR 2 P/N: C144824-1 S/N: 1567). BOTH GEARBOXES WERE REPLACED WITH OVERHAULED AND INSPECTED/TESTED UNITS. FLAP SYSTEM RIG AND OPERATIONAL CHECKS WERE NORMAL. THE AIRCRAFT WAS RELEASED BACK INTO SERVICE.

ATA 2750

Part: CONTROLLER — FAULTY (TE FLAP) · airframe 12,120 hrs · 7,369 cycles

DURING CLIMB OUT FLIGHT CREW RECEIVED A FLAPS FAIL CAS MSG WHILE THE FLAPS WERE IN THE UP POSITION, REPEAT ISSUE. THE DECISION WAS MADE TO DIVERT & AN EMER LANDING WAS DECLARED. AN UNEVENTFUL LANDING WAS ACCOMPLISHED. A FAULTY RT FLAP POSITION RESOLVER PN 9914510-4, DUE TO VOLTAGE CHECK OUT OF TOLERANCE. THE RESOLVER WAS REPLACED & FLAP ELEC RIGGING WAS ACCOMPLISHED. THE FLAP PDU PN 9914615-3 WAS REPLACED & FLAPS ELEC RE-RIGGED. ACFT FAILED THE CONFIDENCE FLIGHT & DIVERTED FOR MX. AN EMER LANDING WAS AGAIN DECLARED, FOLLOWED BY AN UNEVENTFUL LANDING. TROUBLESHOOTING REVEALED A FAULTY FLAP CONTROLLER PN 6718328-1. THE FLAP CONTROLLER WAS REPLACED ALONG WITH THE NR 2 FLAP POSITION SENSOR PN 9914510-4. OPS CHECKS PERFORMED & A MX FLIGHT IS SCHEDULED AT A LATER TIME.