STERLING AVIATION, LLC

1) CREW RECEIVED AMBER WING ANTI-ICE FAIL AND AMBER WING ANTI-ICE VALVE CLOSED MESSAGES DURING OPERATION IN ICING CONDITIONS 2) CREW RETURNED TO HOME BASE 3) MTN TROUBLESHOT RH ANTI-ICE VALVE 4) MTN DEFERRED PER MEL 30-10-01 5) MTN REMOVED LH & RH WING ANTI-ICE VALVES AND REPLACED WITH UPDATED, REPAIRED UNITS 6) OPS CHECKS GOOD.

1) CREW NOTED MOMENTARY MULTIPLE CASCADING CAS MESSAGES FOLLOWED BY CLEARING OF MAJORITY OF MESSAGES WITH FADEC1 FAIL REMAINING IN FLIGHT 2) CREW ELECTED TO RETURN TO BASE. 3) MTN COLLECTED ALMF AND F40B FILES AND SENT TO PILATUS. 4) CAS MESSAGE TRIGGERED BY MOMENTARY LOSS OF DCPU #3 WHICH TRIGGERED L FADEC FAIL FAULT. 5) MTN R&R DCPU #3 WITH INSPECTED UNIT. OPS CHECK GOOD.

ON TAKEOFF FROM IAD UMS DATABASE FAIL INDICATION RECEIVED. CREW ABORTED TAKEOFF AND RETURNED TO FBO. MTN CONTACTED PILATUS SUPPORT. SUSPECT PCU DEFECTIVE. MTN REPLACED #2 PCU WITH NEW UNIT. OPS CHECKS GOOD.

DURING DESCENT ON RETURN FLIGHT TO CLT CREW RECEIVED MAIN BRAKE FAIL CAS MESSAGE. CREW DECLARED AN EMERGENCY, USED LONGEST RUNWAY TO LAND, STOPPED ON RUNWAY AND USED TUG TO RAMP. MTN TROUBLESHOOTING FOUND THIS AS CAUSED BY AN INTERMITTENT QUANTITY SENSOR IN THE HYDRAULIC RESERVOIR. MTN REMOVED AND REPLACED RESERVOIR/SENSOR ASSY WITH SERVICEABLE UNIT. OPS CHECKS GOOD.

1) DURING DESCENT ON FLIGHT TO ELM CREW RECEIVED RH ENG HIGH OIL NOTICE. 2) CREW PERFORMED ENG INFLIGHT SHUTDOWN ON RH ENGINE. 3) CREW DECLARED AN EMERGENCY AND LANDED AT ELM. 4) MTN COMPLIED WITH FHDB AND WI DOWNLOADS. 5) MTN REMOVED AND REPLACED RH OIL PRESSURE TRANSDUCER W/ NEW. LEAK CHECK GOOD.

SUPPLEMENTAL: 1) MTN REMOVED AND REPLACED #3 STARTER GENERATOR, FIELD WIRES, POSITIVE CABLE AND NEGATIVE CABLE. 2) OPS CHECKS GOOD.

NR 3 ENGINE STARTER FAILED AFTER ENGINE START. CREW SHUT DOWN ENGINE PRIOR TO PARKING BRAKE RELEASE. CONTACTED MTN, TROUBLESHOOTING IN PROGRESS. OPEN

PRIOR TO POWER APPLICATION ON TAKEOFF THE NR 2 ENGINE ROLLED BACK. CREW EXITED THE RUNWAY AND RETURNED TO RAMP. MTN REMOVED AND INSPECTED ENGINE. FOUND FUEL NOZZLES UNSERVICEABLE.

DURING TAKE-OFF ROLL PILOT'S PFD WENT BLANK. CREW EXECUTED A LOW SPEED ABORT AND RETURNED TO BED.MTN REMOVED AND REPLACED PILOT'S PFD WITH OVH UNIT. OPS CHECKED GOOD.

1) AFTER DEPARTURE FROM TYS CREW NOTED LOSS OF PRESSURIZATION WHILE CLIMBING THROUGH 8000'. 2) CREW RETURNED TO TYS 3) MTN FOUND BROKEN CABLE IN BAGGAGE DOOR PRESSURE FLAP SYSTEM 4) MTN REMOVED AND REPLACED CABLE WITH NEW 5) PRESSURIZATION AND OPS CHECKS GOOD.

1) CREW NOTED SMOKE IN COCKPIT/CABIN AFTER TAKE OFF. 2) CREW DECLARED AN EMERGENCY AND RETURNED TO SAT. 3) MTN FOUND RH FWD CABIN ELECTRIC HEATER/FAN PCB BURNED. 4) MTN REPLACED RH FWD CABIN ELECTRIC HEATER ASSY WITH NEW.

MANUFACTURER INDICATES A FAILED BRAZE WELD ON THE #1 LPT NOZZLE GUIDE VANE WHICH ALLOWED THE NOZZLE TO FLEX AND CONTACT THE #1 LPT DISK. THIS DAMAGED THE DISK SENDING DEBRIS THROUGH THE REST OF THE TURBINE SECTION CAUSING DAMAGE THROUGHOUT. ENGINEERING IS INVESTIGATING IF THE FAILED WELD WAS THE ROOT CAUSE OR THE RESULT OF SOME OTHER FAILURE, POSSIBLY VIBRATION FROM A BEARING. AFTER REPAIR OF ENGINE NOTED FAILED PART WAS A NOZZLE/HEATSHIELD ASSY.

ON APPROACH CREW NOTED BRAKE FAILURE WITH ANTI-SKID INOP ANNUNCIATOR. CREW STOPPED THE AIRCRAFT WITH EMERGENCY BRAKE LEVER. PERFORMED ROTARY TEST OF ANTISKID SYSTEM, NO FAULTS NOTED. MAINTENANCE PERFORMED OHM READINGS OF LT AND RT WHEEL TRANDUCERS AND NOTED LT WHEEL TRANSDUCER READINGS ERRATIC AND SPIKING. MELD TRANSDUCER AND RETURNED TO HOME BASE. MTN REPLACED LT MAIN WHEEL SPEED TRANSDUCER WITH SERVICEABLE UNIT.

1) ON APPROACH WITH GEAR DOWN CREW NOTED "GEAR" ON MFD AND LH GEAR ANNUN FLICKER TO WHITE UNSAFE POSITION FOR A SECOND. IN THE FLARE AFTER RETARDING POWER HEARD AN AUDIBLE GEAR WARNING 2) MTN CHECKS SHOWED NO DEFECTS ON GROUND. 3) MTN PERFORMED CHECKS ON DOWN AND LOCK MICROSWITCHES FOR RIGGING. FOUND LH MLG SWITCH OUT OF RIG. ADJUSTED SWITCH. 4) COMPLIED WITH GEAR SWINGS WITH NO DEFECTS NOTED.

ON APPROACH TO RIL CREW NOTED FLAPS WOULD NOT DEPLOY. CREW DELCARED AN EMERGENCY AND DIVERTED TO GJT. MAINTENANCE ADJUSTED RIGGING ON LEFT INBOARD FLAP, OPS CHECK GOOD.

1) UPON ARRIVAL IN HDC CREW NOTED A BRAKE FAILURE. STERLING MAINTENANCE CONTROL CONTACTED MAINTENANCE IN HDC. MAINTENANCE REMOVED AND REPLACED BRAKE PUMP WITH REPAIRED UNIT.

1) IN FLIGHT CREW NOTED 200 LB IMBALANCE, OBSERVED FUEL LEAKING FROM LH WINGTIP AREA 2)CREW DIVERTED TO BHM 3)LANDING WAS UNEVENTFUL 4) STERLING MTN WITH PILATUS TECH SUPPORT DETERMINED THE ISSUE WAS CAUSED BY EXCESSIVE PRESSURE DURING FUELING CAUSING FUEL TO BE FORCED INTO THE CLIMB VENT LINE. ONCE AIRBORNE DIFFERENTIAL PRESSURE CAUSED THIS FUEL TO BE SIPHONED OUT UNTIL FUEL LEVEL DROPPED BELOW LEVEL OF VENT OUTLET DURING DESCENT. 5)LEAK CHECK OF SYSTEM REVEALED NO CURRENT LEAKS 6)AIRCRAFT RELEASED TO CLT

1) DURING TAKEOFF ROLL CREW RECEIVED MASTER WARNING. 2) CREW ABORTED TAKEOFF, RETURNED TO RAMP. 3) MAINTENANCE TROUBLESHOT TO #2 INVERTER 4) MAINTENANCE REMOVED AND REPLACED #2 INVERTER 5) OPS CHECKS GOOD.

ON TAXI OUT CREW NOTED AIRCRAFT ATTITUDE MISCOMPARE. AIRCRAFT RETURNED TO BLOCK. MAINTENANCE DETERMINED #2 VERTICAL GYRO HAD FAILED. #2 VERTICAL GYRO REPLACED WITH OVH UNIT. OPERATIONAL TEST OF #2 VERTICAL GYRO GOOD.

AFTER TAKE-OFF LANDING GEAR WOULD NOT RETRACT. CREW DECLARED AN EMERGENCY AND RETURNED TO CHS. MAINTENANCE TROUBLESHOT TO DEFECTIVE HYDRAULIC PRESSURE REGULATING VALVE. PRESSURE REGULATING VALVE WAS REPLACED WITH AN OVERHAULED UNIT. PERFORMED MULTIPLE EXTENSION/RETRACTION CYCLE TESTS. OPS CHECKS GOOD.

DURING PILOTS PRE-FLIGHT INSPECTION A PORTION OF THE MIXER CASE ASSEMBLY WAS OBSERVED IN THE FAN AIR BYPASS DUCT OF THE RIGHT HAND ENGINE. FURTHER INVESTIGATION DISCOVERED MULTIPLE CRACKS AND MISSING SECTIONS OF THE ASSEMBLY. THE LEFT HAND ENGINE MIXER CASE ASSEMBLY WAS OBSERVED TO HAVE CRACKING AND MISSING SECTIONS AS WELL.

AFTER TAKE-OFF CREW NOTED RT ENGINE ANTI-ICE FAIL INDICATION. CREW RETURNED TO HOME BASE. MX TROUBLESHOT. REPLACED RT ENGINE INLET ANTI-ICE SOLENOID VALVE WITH REPAIRED UNIT. OPS CHECKED GOOD

AFTER STARTING BOTH ENGINES CREW NOTED 5% SPLIT IN N2 INDICATIONS. CREW ADVANCED POWER ON BOTH ENGINES TO BEGIN TAXIING OUT OF PARKING, ONLY RT ENGINE WOULD ADVANCE IN POWER. CREW SHUT DOWN BOTH ENGINES AND CONTACTED MX. MX TROUBLESHOT AND NOTED NR 1 FUEL CONTROL REQUIRES REPLACEMENT. REMOVED AND REPLACED WITH OVH UNIT. OPS CHECKS GOOD.

1) AFTER DEPARTING CLT CREW REPORTED BOTH #1 COMM AND #2 COMM HAVE HEAVY STATIC DURING CLIMBOUT AND INTERMITTENT AT LEVEL FLIGHT. MODERATE PRECIP THROUGHOUT THE FLIGHT. 2) CREW RETURNED TO HOME BASE. LANDING WAS UNEVENTFUL. 3) TECHNICIANS TESTED ALL STATIC WICKS AND FOUND SEVERAL IN NEED OF REPLACEMENT DUE TO EROSION OR FAILURE DURING TESTING. 4) REMOVED AND REPLACED ALL WICKS AT THE LH & RH AILERON, WING TIP AND ELEVATOR WITH NEW. REMOVED AND REPLACED 3 ON RUDDER WITH NEW. TESTED WITH NO FURTHER DEFECTS.

1) AFTER DEPARTING DTS HAD A RIGHT ROLL TRIM FAIL MESSAGE AND LEFT ROLL TRIM INTERMITTENT. 2) CREW DIVERTED TO TPA 3) CONSTANT AVIATION TROUBLESHOT AND FOUND RH SIDE FROZEN AT NEUTRAL. 4) REMOVED RH ROLL TRIM ACTUATOR AND REPLACED WITH OVH UNIT. OPS CHECKS GOOD.

ON STARTUP CREW RECEIVED NWS FAIL CAS MESSAGE. CREW SHUT DOWN AND RESTARTED - MESSAGE REMAINED. CREW RETURNED TO GATE. TROUBLESHOT AND FOUND NWS RVDT INOP. REMOVED AND REPLACED NWS RVDT WITH REPAIRED UNIT. OPS CHECKS GOOD.

1) ON APPROACH WITH LANDING GEAR SELECTED DOWN THE 3 DOWN AND LOCKED INDICATOR LIGHTS DIDN'T ILLUMINATE 2) CREW ABORTED APPROACH TO ASSESS SITUATION 3)CREW FOUND 2 AMP LANDING GEAR WARNING CB TRIPPED. CREW ATTEMPTED ONE TIME RESET FOR CHECKLIST AND DOWN AND LOCKED LIGHTS ILLUMINATED FOR SEVERAL SECONDS BEFORE CB TRIPPED AGAIN. 4)CREW PERFORMED FLY BY OF TOWER, TOWER AND ANOTHER AIRCRAFT WAITING TO DEPART VISUALLY OBSERVED LANDING GEAR APPEARED DOWN AND LOCKED 5) CREW DECLARED AN EMERGENCY AND PROCEEDED WITH LANDING. LANDING WAS UNEVENTFUL. 6) STERLING AVIATION MAINTENANCE CONTROL CONTACTED TO TROUBLESHOOT. 7) PERFORMED 10 PLUS LANDING GEAR RETRACTION, EXTENSION CYCLES WITH NORMAL OPERATION, CB DIDN'T TRIP. INSPECTED UPLOCK AND DOWNLOCK SWITCHES AND ALL ASSOCIATED WIRING. NO DEFECTS NOTED. COMPLETED UPLOCK AND DOWNLOCK SWITCH PARALLELING CIRCUIT TESTS. NO DEFECTS NOTED. 8) TECHNICIANS ARE CONTINUING TROUBLESHOOTING EFFORTS. SUPPLEMENTAL: TECHNICIANS TROUBLESHOT AND FOUND LEFT MAIN LANDING GEAR WIRE HARNESS CHAFING ON HYDRAULIC LINE. REPAIRED WIRING. OPS CHECKED GOOD.

CREW RECEIVED "CHECK OIL" AND "OIL PRESS 3" CAS MESSAGE IN FLIGHT. CREW SHUTDOWN #3 ENGINE, DECLARED EMERGENCY AND DIVERTED. FOUND OIL COOLER SUPPLY LINE CRACKED, NON-MAGNETIC MATERIAL IN INLET AND MAGNETIC DEBRIS IN TRANSFER GEARBOX. REPLACED OIL COOLER SUPPLY LINE WITH NEW P/N 3061253-5.

1)ON CLIMBOUT CREW NOTED CABIN PRESSURIZATION NOT HOLDING CORRECT CABIN ALTITUDE. 2)CREW RETURNED TO HOME BASE. 3)MAINTENANCE TROUBLESHOT AND FOUND THE AIR CYCLE MACHINE DUCT COUPLER COMING LOOSE. 4) RESECURED DUCT COUPLER, OPS CHECK GOOD.

1) DURING CLIMB PILOT NOTED NR 1 DEEC CAS MESSAGE. 2) PILOT RETURNED TO HOMEBASE. 3) MAINTENANCE INSPECTED AND REPLACED NR 1 FUEL CONTROL 4) AIRCRAFT RETURNED TO SERVICE.

DURING LIVE LEG PILOT NOTED AIR CONDITIONING WASN'T WORKING. LANDING IN CZBM WAS UNEVENTFUL. TECHNICIANS TROUBLESHOT TO BAD CURRENT LIMITER AND VCCS MOTOR. REMOVED AND REPLACED MOTOR. OPERATIONS CHECKS GOOD. AIRCRAFT RETURNED TO SERVICE.

ON POST FLIGHT AFTER FIRST LEG OF TRIP CREW NOTED A SECTION OF RIGHT ENGINE EXHAUST FLUME DAMAGED. CONTACTED OFFSITE MAINTENANCE FOR SUPPORT. CONTACTED ENGINE MANUFACTURER FOR REPAIR SCHEME. DRESSED OUT DAMAGE IN ACCORDANCE WITH SERVICE LETTER SL44-72-481.

DURING DEPARTURE TAXI, CREW NOTICED THE COPILOT PFD BUTTON STUCK IN TEST MODE. CREW RETURNED TO BLOCKS. MAINTENANCE CLEANED THE SELECTOR SWITCH. OPS CHECKED GOOD.

CREW CALLED SAYING THEY HAVE A COMPUTER ISSUE WITH RUDDER DEFLECTION NOTIFICATION ON GROUND DURING PREFLIGHT INSPECTION. DETERMINED THE POSITION TRANSMITTER FLEXIBLE COUPLER WAS UNSERVICEABLE. REPLACED THE FLEXIBLE COUPLER WITH NEW. OPS CHECKED GOOD.

DURING INSPECTION, NOTED THE NOSE GEAR DOORS WAS SAGGING. FURTHER INSPECTION FOUND TORQUE TUBE WELD ASSY BROKEN AT THE WELD. REPLACED TORQUE TUBE WITH NEW.

DURING TAKEOFF ROLL, CREW NOTED UNCOMMANDED HOT AIR COMING INTO CABIN AND FLUCTUATIONS IN CABIN PRESSURIZATION RATE. RETURNED TO BASE, LANDING WAS UNEVENTFUL. TROUBLESHOT AND FOUND EMERGENCY PRESSURE VALVE INTERMITTENT. REPLACED THE VALVE WITH AN OVERHAULED UNIT. OPS CHECKED GOOD.

AFTER TAKEOFF, CREW NOTED UNCOMMANDED HOT AIR COMING INTO CABIN AND FLUCTUATIONS IN CABIN PRESSURIZATION RATE. RETURNED TO BASE, LANDING WAS UNEVENTFUL. COULD NOT DUPLICATE. AIRCRAFT RETURNED TO SERVICE. NO DISCREPANCIES ON RETURN FLIGHT.

PRIOR TO DEPARTURE, PILOT NOTED ONE RADIO NOT WORKING. REMOVED AND REPLACED THE NR 1 VHF COM MODULE. OPS CHECKED GOOD.

NO TAKEOFF CAS MESSAGE - ROLL SYSTEM CAS IN NO TAKEOFF PAGE NOTED WHILE TAXIING. CREW RETURNED TO HOME BASE. REMOVED AND REPLACED AILERON RATIO ACTUATOR PROXIMITY SWITCH. OPERATIONS CHECKED GOOD.

5 MINUTES AFTER TAKEOFF RIGHT SIDE BLEED AIR ANNUNCIATOR CAME ON DURING FLIGHT. CREW RETURNED TO DEPARTURE. LANDING WAS UNEVENTFUL. TROUBLESHOT AND FOUND BLEED AIR PRESSURE SWITCH FAILED. REPLACED THE SWITCH, OPS CHECKED GOOD.

10 MINUTES INTO FLIGHT, THE LEFT ENGINE LOWER SQUIB LIGHT ILLUMINATED. CREW RETURNED TO DEPARTURE. LANDING WAS UNEVENTFUL. MAINTENANCE FOUND LEFT AFT FIRE LOOP HAD FAILED AND REPLACED THE FIRE LOOP. OPS CHECKED GOOD.

THE AIRCRAFT ARRIVED FOR UNRELATED MAINTENANCE WHEN IT WAS NOTED THAT A LARGE AMOUNT OF FUEL WAS EMANATING FROM THE BELLY AREA BETWEEN THE WHEEL WELLS. ACCESS WAS GAINED TO THE AREA BETWEEN THE WHEEL WELLS CONTAINING THE MAIN FUEL SHUTOFF VALVES. WITH BOOST PUMPS ON, FUEL WAS OBSERVED TO COME FROM THE LEFT SHUTOFF VALVE. IT WAS INITIALLY THOUGHT THE O-RING BETWEEN THE MATING SURFACES OF THE ADAPTER AND SHUTOFF VALVE HAD FAILED. UPON DISASSEMBLY FOR REPLACEMENT OF THE SUSPECTED O-RING, IT WAS FOUND THAT THE ADAPTER, MADE FROM PLASTIC, FROM THE SHUTOFF VALVE TO THE HARD FLUID LINE TO THE ENGINE HAD A CRACK APPROXIMATELY 90 DEGREES OF CIRCUMFERENCE BETWEEN THE VALVE MATING FLANGE AND PIPE FLANGE. NEW REPLACEMENTS WERE ORDERED AND INSTALLED FOR BOTH LEFT AND RIGHT SHUTOFF VALVES. THE REAR EQUIPMENT COMPARTMENT WAS CLEANED AND DRIED OF A LARGE AMOUNT OF FUEL. THE REPLACEMENTS ARE ALSO CONSTRUCTED FROM PLASTIC. IT IS THE OPINION OF THE SUBMITTER THAT A PART THIS CRITICAL IN NATURE BE CONSTRUCTED FROM A MORE SUBSTANTIAL MATERIAL TO PREVENT UNCONTROLLED LOSS OF FUEL WHILE FILLING A COMPARTMENT CONTAINING ELECTRICAL MOTORS AND EQUIPMENT WITH FUEL.

WHILE ENROUTE, CREW NOTED MAU1 FAIL. CREW DIVERTED, CONTACTED MAINTENANCE FOR SUPPORT, REPLACED NR1 DUAL NIC PROCESSOR. OPS CHECK GOOD.

RIGHT GENERATOR SPIKED TO 450 AMPS. CREW RAN CHECKLIST, SWITCHED TO OFF, AMPS DECREASED TO 25 ON RT AND 185 ON LT. AFTER SHUTDOWN WITH ONLY BATTERY ON, RT AMPS INDICATED 120+. RETURNED TO DEPARTURE FOR MAINTENANCE. REPLACED THE CURRENT SENSOR. OPS CHECKED GOOD.

ON APPROACH, CREW EXPERIENCED HYDRAULIC QTY LOW LIGHT FOLLOWED BY HYDRAULIC PRESSURE AND BOTH HYDRAULIC PUMP LIGHTS INTERMITTENTLY ON LANDING. CREW ALSO NOTED INTERMITTENT BRAKING AND NOSE STEERING DIFFICULTIES. MAINTENANCE SUSPECTS SPEED BRAKE LINE IS LEAKING, CONTINUING TO TROUBLESHOOT. MAINTENANCE VERIFIED RT SPEED BRAKE HYDRAULIC PRESSURE LINE HAD FAILED. REPLACED FAILED LINE AND BLEED HYDRAULIC SYSTEMS. OPS AND LEAK CHECK GOOD.

ON TAXI OUT WHILE COMPLYING WITH RUDDER BIAS CHECK WITH THE ENGS AT POWER, CREW RECEIVED MASTER WARNING HORN. CREW RETURNED THROTTLES TO IDLE, NO CHANGE. CREW PULLED BREAKER & MASTER WARNING HORN STOPPED. CREW RETURNED FOR MX. MX POWERED ACFT NORMALLY & FOUND MASTER WARNING HORN DID NOT SOUND. ALL SYSTEMS OPERATING NORMALLY. ACFT RETURNED TO SERVICE.

AFTER TAKEOFF, THE CREW RECEIVED AN APU FIRE WARNING. CREW DISCHARGED APU FIRE BOTTLE & RETURNED. FIRE WARNING DIDN'T CANCEL WHEN FIRE BOTTLE WAS DISCHARGED, SO CREW DECLARED AN EMER & EVACUATED ACFT ON THE RUNWAY. INSPECTION REVEALED NO EVIDENCE OF FIRE IN APU AREA. ACFT REPOSITIONED FOR INVESTIGATION OF FALSE FIRE WARNING. FOUND WIRE SHORTED AT APU LOWER FWD OVERTEMP SWITCH. REPAIRED WIRE. OPERATIONS CHECKED GOOD.

ENROUTE CREW NOTED A VIBRATION FROM LT ENG. CREW DIVERTED & LANDING WAS UNEVENTFUL. CONTACTED MFG FOR SUPPORT. MFG COMPLETED VIBRATION SURVEY & DETERMINED LT ENG FAN REQUIRED BALANCING. REMOVED FAN BLADES, LUBED DOVETAILS & REINSTALLED. BALANCED FAN. OPERATIONS CHECKED GOOD.

ON APPROACH, THE CREW DID NOT HAVE A LT MAIN DOWN & LOCK INDICATION. DECLARED AN EMER, LANDING WAS UNEVENTFUL. FOUND INDICATOR LAMP HAD FAILED. REPLACED BULB, OPERATIONS CHECKED GOOD.

ON DEPARTURE, CREW NOTED LOUD SQUEAL FROM CABIN DOOR AREA. CREW RETURNED & LANDING WAS UNEVENTFUL. INSPECTED AREA & FOUND DOOR SEAL FAILED. DOOR SEAL WAS REPLACED. FUNCTIONAL CHECKED GOOD.