COBALT AIR, LLC

DURING CRUISE FROM KIAD TO KCEU, CREW NOTED A LOUD BANG FROM THE ENG AREA. THE CREW DIVERTED TO KCLT & ATC DECLARED AN EMER, LANDING UNEVENTFUL. TECHS VISUALLY INSPECTED THE ENG FOR DEFECTS & COMPLIED WITH A BORO INSP IAW EMM 72-00-00 & FOUND IN LIMITS. INSPECTED AIR INLET SCREEN FOR DAMAGE & NONE NOTED, IAW EMM 72-20-00. INSPECTED COMPRESSOR & COMPRESSOR STATOR FOR DAMAGE IAW EMM 72-30-05 & FOUND IN LIMITS. ACCOMP ENG RUN IAW AMM 12-B-71-00-00-00A-903A-A TESTS 1, 7, 19, & 20, PERFORMANCE CHKD GOOD. NO LEAKS OR DEFECTS NOTED, NO FURTHER RECOMMENDATIONS FROM TECHNICAL SUPPORT. ACFT RELEASED FOR SERVICE. MANUFACTURER SUGGESTS THAT POTENTIALLY ICING BUILDUP ON THE INLET SCREEN CAUSED THE NOISE.

CREW BEGAN DESCENT FROM FL230 AND AT AROUND FL200 HAD AN ACS LOW INFLOW CAS AND SAW THE CABIN ALTITUDE RISING. REQUESTED AN EMERGENCY DESCENT TO 10000 AND RESET THE ACS SYSTEM. ACS CAME BACK ONLINE NORMALLY AFTER THE DESCENT AND LANDING WAS UNEVENTFUL.

DURING A REPOSITION FLIGHT OUT OF KOJC, AN AMBER FUEL PRESSURE LOW (CAS) DISPLAYED ON TAKE OFF ROLL RESULTED IN A REJECTED TAKE OFF. MAINTENANCE IS BEING CARRIED OUT AND A SUPPLEMENTAL SDR WILL BE FILED WITH THE SAME UNIQUE CONTROL NUMBER WHEN A RESOLUTION IS AVAILABLE.

AFTER A REPAIR TO THE FUEL SYSTEM FOR CONTAMINATION AND THE AIRCRAFT RELEASED TO SERVICE, DURING THE FIRST SCHEDULED DEPARTURE FROM KOJC ON THE TAKE-OFF ROLL, THE CREW NOTED A "FUEL PRESSURE LOW" CAS MESSAGE. THE CREW ABORTED THE TAKEOFF AND RETURNED TO THE APRON. THE CREW ALSO NOTED FUEL LEAKING UNDER THE INBOARD AREA OF THE LEFT WING AFTER RETURNING TO THE FBO. TECHNICIANS FOUND A LOOSE DELIVERY EJECTOR FUEL LINE FITTING IN THE LH WING UNDER PANEL 51AB. THE LINE WAS TIGHTENED AND LEAK CHECKED WITH NO FURTHER DEFECTS NOTED.

AT TAKEOFF FROM KF45, THE CREW NOTED A BURNING RUBBER SMELL. THE CREW DECIDED TO ABORT THE TAKEOFF. TECHS DETERMINED IT TO BE RELATED TO THE ACS SYSTEM. THE ACS SYSTEM HAS BEEN DEACTIVATED. TECHS AT KPSM FOUND THE WATER SEPARATOR TO HAVE HEAVY CONTAMINATION. R & R WATER SEPARATOR IAW AMM 12-B-21-40-03-00A-920A-A & PERFORMED ENGINE TEST 18 IAW AMM 12-B-71-00-00-00A-903S-A WITH NO FURTHER DEFECTS.

DURING APPROACH AFTER A ROUTINE FLIGHT FROM KDAL TO KSFB, THE CREW NOTED A MAIN BRAKES FAIL CAS MESSAGE. THE CREW FOUND THE SYSTEM PRESSURE AT 2100 PSI AND THE PUMP NOT RAISING THE PRESSURE TO NORMAL LEVELS. FOLLOWING THE QRH, THE CREW LANDED AT KSFB WITHOUT INCIDENT. THERE WAS SUFFICIENT PRESSURE TO STOP ON THE TAXIWAY AND GET TOWED TO THE FBO. TECHNICIANS REMOVED AND REPLACED THE HYDRAULIC RESERVOIR IAW PILATUS AMM PC24-A-E32-40-0011-00A-520A-A AND PC24-A-E32-40-0011-00A-720A-A. OPS CHECK GOOD. LEAK CHECK GOOD.

DURING A PART 91 FLIGHT FROM KSWO TO KBTA, AT 1000 FL THE CREW NOTED A CAS MESSAGE FOR FUEL IMBALANCE WITH FOUR BARS DIFFERENCE BETWEEN LEFT AND RIGHT SIDE. ADDITIONALLY, WITH THE AUTOPILOT DISCONNECTED, THE AIRCRAFT ROLLS LEFT. THE CREW DIVERTED TO KOJC AND LANDED WITHOUT INCIDENT. MAINTENANCE TROUBLESHOOTING WILL BE PERFORMED AND THIS SDR WILL BE UPDATED.

DURING CRUISE FROM KTEX TO KGPI, THE CREW NOTED THE MAIN/EMERGENCY BRAKE PRESSURE TO BE DROPPING. THE CREW DECIDED TO DIVERT TO KAPA. DURING APPROACH, THE CREW NOTED A MAIN BRAKE FAIL CAS WITH A TRIPPED ECB. THE ECB TRIPPED IMMEDIATELY AFTER THE FIRST ATTEMPT TO RESET IT. THE CREW MADE A SUCCESSFUL LANDING WITHOUT FURTHER INCIDENT. TECHNICIANS REPLACED THE PARKING BRAKE VALVE P/N 959.47.51.129 S/N OFF 0336, S/N ON 0347, AND THE BRAKE PUMP MOTOR P/N 960.30.01.173 S/N OFF 0431, S/N ON 0235 MOD B.

DURING A ROUTINE FLIGHT FROM KTPA TO KOSU, AT FL270, THE CREW NOTED AN ACF LOW INFLOW CAS FOLLOWED BY THE CABIN NOT MAINTAINING ALTITUDE. AN EMERGENCY WAS DECLARED AND THE CREW DIVERTED TO KLOZ WHERE THEY LANDED SAFELY WITHOUT FURTHER INCIDENT. THE ECS SYSTEM WAS DEFERRED TO FLY IT TO KATL WHERE MAINTENANCE WILL BE PERFORMED. OPEN

DURING A ROUTINE FLIGHT FROM KPSM TO KBTV, THE CREW EXPERIENCED DURING CLIMB THE YAW DAMP WOULD NOT ENGAGE. ON THE THIRD ATTEMPT TO ENGAGE THE YAW DAMP, AP FAIL CAS MESSAGE FOLLOWED 2 SECONDS LATER BY A RED TRIM RUNAWAY CAS. AN EMERGENCY WAS DECLARED AND THE AIRCRAFT RETURNED TO KPSM WHERE THERE WAS AN UNEVENTFUL LANDING. TECHNICIANS REMOVED AND REPLACED THE YAW TRIM ADAPTER SSSD RELAY A262K4 IAW WDG 91-10-08. PERFORMED A/P ADJ/TEST IAW AMM-12-C-22-10-00-00A-903A-A WITH NO DEFECTS.

DURING A SCHEDULED FLIGHT FROM KBVU TO KIWS, THE CREW WAS CLIMBING OUT OF KBVU AND CREW NOTED THAT THE LANDING GEAR WOULD NOT RETRACT. THEY FOUND THE CIRCUIT BREAKER FOR THE LANDING GEAR WAS OUT. THE CREW DIVERTED BACK TO KBVU AND LANDED WITHOUT INCIDENT. TECHNICIANS RESET THE CIRCUIT BREAKER AND FUNCTIONALLY TESTED THE SYSTEM IAW PILATUS AMM 12-B-32-30-00-00A-903B-A AND FOUND NO FAULTS, NO CAS MESSAGES, AND THE CIRCUIT BREAKER REMAINED ENGAGED.

DURING A ROUTINE REPOSITIONING FLIGHT FROM KCHS TO KBCT, THE CREW REPORTED A "BATTERY 1 HOT CAS" MESSAGE. THE CREW DECLARED AN EMERGENCY AND DIVERTED TO KVRB, LANDING WITHOUT ANY FURTHER INCIDENT. TECHNICIANS REPLACED THE #1 BATTERY P/N 31406-002 S/N 11901249 WITH AN INSPECTED/TESTED BATTERY P/N 31406-002, S/N 12101409 IAW AMM 12-B-24-30-07-00A-920B-A. THE FAULTY BATTERY WILL BE DISASSEMBLED AND INSPECTED/TESTED TO FURTHER VERIFY FAULTS WITH THE TEMPERATURE SENSOR.

DURING A ROUTINE TAKEOFF AT KLUK, THE CREW REPORTED: DURING T/O AT 12 PSI HEARD BANG / (NP) WENT BELOW 1000 / BLACK SMOKE CAME OUT THE RIGHT EXHAUST STACK & AMBER ENGINE NP (CAS) DISPLAYED. THE CREW REPORTS THEY SHUT THE ENGINE DOWN AND IT DID NOT SEIZE AFTER THE EVENT. TECHNICIANS ARRIVED FOR AN INSPECTION AND FOUND DENTS/HOLES FROM THE INSIDE OF THE L/H AND R/H EXHAUST STACKS. NO EVIDENCE OF DAMAGE FROM DEBRIS FOUND ON THE AIRFRAME. NO DAMAGE VISIBLE ON THE EXTERIOR OF THE GAS GENERATOR OR POWER SECTION. CONFIRMED ALL CONTROL LINKAGES, FUEL LINES, OIL LINES, AND PNEUMATIC LINES WERE PROPERLY INSTALLED AND SECURE. PERFORMED A BORESCOPE INSPECTION OF THE FIRST STAGE COMPRESSOR IAW PRATT AND WHITNEY EMM 72-00-00. NO DEFECTS NOTED. NO EVIDENCE OF INGESTION NOTED ON INLET SCREENS OR COMPRESSOR BLADES. REMOVED FUEL NOZZLE #13 AND REMOVED THE NUTS FROM #12 TO FACILITATE HOT SECTION BORESCOPE IAW PRATT AND WHITNEY EMM 73-11-01. PERFORMED A HOT SECTION BORESCOPE IAW PRATT AND WHITNEY EMM 72-00-00. NO DEFECTS NOTED. PERFORMED A BORESCOPE INSPECTION OF THE 2ND STAGE POWER TURBINE FROM THE EXHAUST STACK IAW PRATT AND WHITNEY EMM 72-00-00. FOUND ALL VISIBLE ROTOR AND STATOR BLADES DAMAGED, WITH SOME BLADES MISSING SIGNIFICANT MATERIAL. PERFORMED AN INSPECTION OF THE RGB CHIP DETECTOR IAW P&WC EMM 72-00-00, TABLE 601, 3A(8). NO DEBRIS OR OTHER DEFECTS NOTED. PERFORMED AN INSPECTION OF THE OIL FILTER IAW P&WC EMM CHAPTER 79-20-02. NO DEBRIS OR OTHER DEFECTS NOTED. THIS ENGINE IS INTENDED TO BE REPLACED BY A PRATT & WHITNEY MRT. OPEN

DURING CLIMB FOR A ROUTINE FLIGHT FROM KGVL TO MYAM, THE CREW REPORTED A "CNTL" CAS MESSAGE AFTER SELECTING LANDING GEAR TO THE UP POSITION. THE CREW PERFORMED THE QRH PROCEDURE AND RECEIVED 3 GREEN DOWN-AND-LOCKED INDICATIONS AND MADE A DIVERSION TO KPDK WITH NO FURTHER INCIDENTS. TECHNICIANS FOUND THE NOSE LANDING GEAR STRUT FAILED TO EXTEND FULLY AFTER TAKE-OFF, CAUSING THE NOSE GEAR NOT TO RETRACT INTO THE BAY FULLY. THE TECHNICIANS REPLACED THE BARREL NUT, SCRAPER RING, AND ASSOCIATED SEALS IAW THE CMM 32-20-05. FUNCTIONAL AND OPERATIONAL CHECKS WERE SATISFACTORY.

DURING A FLIGHT FROM PHL TO FOK, THE CREW NOTED A PIECE OF THE COPILOT. WINDSHIELD SEALANT SEPARATED. THE CREW DECIDED TO DECLARE AN EMERGENCY AND DIVERT TO JFK. A TECHNICIAN REMOVED AND REPAIRED THE LIFTING COPILOT'S WINDSHIELD EDGE SEAL IAW PILATUS AMM 12-B-20-50-03-00A-901A-A WITH NO FURTHER DEFECTS NOTED.

DURING CRUISE AT 26000 FT IN VFR CONDITIONS, THE CREW REPORTED A BURNING OIL ODOR IN ACS SYSTEM. AN EMERGENCY DECLARED AND THE CREW DIVERTED TO KBWI. OXYGEN WAS USED BY THE CREW AND PASSENGER AT THIS TIME. LANDING WAS UNEVENTFUL. NO ABNORMAL ENG INDICATIONS OR CAS MESSAGES NOTED, NO EXTERNAL LEAKS OR OIL LEVEL CHANGE WAS NOTED BY THE CREW DURING POST FLIGHT INSPECTION. TECHS EXAMINED THE ENGINE BEHIND THE BLEED VALVE & INSIDE INLET AND NOTED IT TO BE DRY. THE AGB/EXHAUST BREATHER TUBE SHOWED SIGNS OF OIL INDICATING OIL OVER-SERVICING. WATER SEPARATOR REMOVED, INSPECTED, & REPLACED AS A PRECAUTION, BUT NO DEFECTS FOUND. NO SMELL WAS NOTED DURING RUNS, OPS & LEAK CHECK GOOD.

THE CREW WAS DEPARTING DURING A SCHEDULED FLIGHT FROM KPDK ORIGINALLY DESTINED FOR KLFT. WHEN THE LANDING GEAR WAS SELECTED "UP," AND RETRACTED, THE LH LANDING GEAR AMBER X "UNSAFE" CONDITION WAS SHOWN. THE CREW EXTENDED THE GEAR NORMALLY AND RETURNED TO KPDK WITHOUT FURTHER INCIDENT. TECHNICIANS FOUND NO FAULTS AFTER PERFORMING AN OPERATIONAL CHECK OF THE LANDING GEAR SYSTEM IAW PILATUS AMM 12-B-32-30-00-00A-903B-A.

THE CREW DEPARTED FROM KSEZ ON A ROUTINE PASSENGER FLIGHT TO KPAE. DURING CRUISE AT 40,000 FEET, THE CREW NOTED FUEL COMING FROM THE LEFT-HAND WING. BASED ON RECOMMENDATIONS BY PILATUS, TECHNICIANS REPLACED THE FLOAT VALVE PN ON/OFF: 963.82.21.320; SN:F13 WITH NEW SN:0432, IAW AMM PC24-A-E28-20-0011-00A-520A-A AND PC24-A-E28-20-0011-00A-720A-A. COMPLETED FLOAT VALVE OPERATIONS CHECK IAW PC24-A-E28-20-0011-00A-320A-A. NO DEFECTS WERE NOTED. PILATUS HIGHLIGHTED SERVICE LETTER 059 AS A FIX TO THIS ISSUE, HOWEVER, THE SUPERSEDING PART NUMBER 963.82.21.323 WAS NOT AVAILABLE. THE REMOVED PART SHOWED SIGNS OF A WORN FLOAT HINGE AND A FAILED TEFLON SEAL.

THE FLIGHT CREW WERE DEPARTING CYTZ FOR KBED. THE CREW REPORTED "STICK SHAKER ACTIVATED IMMEDIATELY AFTER TAKEOFF ALONG WITH AURAL "STALL" CALLOUT. CREW RETURNED TO DEPARTURE AIRPORT AND SHAKER STAYED ON UNTIL TOUCHDOWN." THE CREW DECLARED AN EMERGENCY AND DIVERTED BACK TO CYTZ AND LANDED WITHOUT INCIDENT. TECHNICIANS FOUND THE LH AOA TRANSMITTER TO BE INTERNALLY DISCONNECTED. THEY REPLACED THE AOA WITH AN OVERHAULED UNIT. OPERATIONAL CHECK WAS PERFORMED SATISFACTORY IAW PILATUS AMM 12-C-22-20-00-00A-903A-A.

DURING APPROACH TO KTEB, THE CREW PLACED THE LANDING GEAR HANDLE TO THE DOWN POSITION. THE LEFT MAIN LANDING GEAR LIGHT REMAINED "IN TRANSIT." THE CREW DECLARED AN EMERGENCY AND CONTINUED THE APPROACH. JUST PRIOR TO LANDING, THE "IN TRANSIT" LIGHT EXTINGUISHED AND THE CREW SAW A "DOWN AND LOCKED" CONDITION. THEY LANDED WITHOUT INCIDENT. THE AIRCRAFT WAS FERRIED TO KPSM FOR MAINTENANCE. THE TECHNICIAN CORRECTED THE DISCREPANCY WITH THE FOLLOWING: "“PERFORMED OPS CHECK OF MLG SYSTEM IAW PILATUS AMM 12-B-32-30-00-00A-903B-A, UNABLE TO DUPLICATE FAULT, MX CONTROL AND MX MANAGEMENT REQUESTS CHANGE OF LH MLG ACTUATOR. REMOVED AND REPLACED LH MLG ACTUATOR IAW PILATUS AMM SECTION 12-B-32-30-01-00A-920B-A. OPS CHECK OK. NO DEFECTS NOTED." THE ACTUATOR WAS SUSPECTED AS THE CAUSE DUE TO THE HIGH TIME AND CYCLE COUNT.

DURING A FLIGHT FROM KBED TO KPHL, THE FLIGHT CREW REPORTED A DU3 FAILURE WITH AN ASSOCIATED STANDBY BUS CAS MESSAGE. THEY DECLARED AN EMERGENCY AND DIVERTED TO KMIV, LANDING UNEVENTFULLY. TECHNICIANS REPLACED THE LEFT POWER JUNCTION BOX AND OPERATIONALLY CHECKED EVERYTHING SATISFACTORY.

WHILE OVER ORD AT FL240, AIR CYCLE SYSTEM (ACS) LOW INFLOW CAUTION ADVISORY SYSTEM (CAS) MESSAGE WAS TRIGGERED, ACCOMPANIED BY AN AUDIBLE CHANGE IN THE AIRCRAFT’S PRESSURIZATION SYSTEM. CREW REFERRED TO QUICK RESPONSE HANDBOOK (QRH) AND SUCCESSFULLY RESET THE ACS. APPROXIMATELY FIVE MINUTES LATER, THE SAME CAS MESSAGE REAPPEARED. CREW DONNED O2 MASKS AND INSTRUCTED PASSENGERS DO SAME. CREW DECLARED AN EMERGENCY WITH CHICAGO CENTER, EXECUTED AN EMERGENCY DESCENT TO 10,000 FEET, LEVELED OFF. HIGHEST CABIN ALTITUDE REACHED DURING THIS DESCENT WAS APPROXIMATELY 9,800 FEET. THE CREW CONTINUED FLIGHT TO DESTINATION AT 10,000 WITH AN UNEVENTFUL APPROACH AND LANDING. (MECHANICAL) POST FLIGHT, MAINTENANCE DISCOVERED FAULTY SWITCH IN ACS. REMOVED DUCT OVER-TEMP SWITCH PN 973.81.32.214 SN 1968. INSTALLED NEW SWITCH PN 973.81.32.214 SN 2077 IAW PILATUS AMM 12-B-21-40-06-00A-920-A-A. OPERATIONAL TESTS CHECK GOOD.

DURING TAKEOFF FROM KBOS ON A ROUTINE FLIGHT TO KHPN, THE LANDING GEAR FAILED TO RETRACT WITH THE SELECTOR HANDLE STUCK IN THE DOWN POSITION. THERE WERE NO WARNING INDICATORS OR CIRCUIT BREAKERS TRIPPED. THE CREW SAFELY DIVERTED TO KPSM. TECHNICIANS TROUBLESHOT THE SYSTEM AND FOUND THE SELECTOR SOLENOID A1213P (P/N 974.61.01.103) WAS INTERNALLY OPEN ACROSS PIN 9 AND 10 WHICH CAUSED THE FAILURE.

IN CRUISE FLT, CREW & PAX BECAME AWARE OF A BURNING PLASTIC SMELL IN COCKPIT & CABIN. CAPT REPORTED DID NOT SEE ANY SMOKE. CLOSE TO KCHA AND CHOSE TO DIVERT. CREW DID NOT DECLARE AN EMERGENCY. BURNING SMELL IN COCKPIT, VISIBLE SMOKE IN CABIN. SEEMED TO ORIGINATE FROM THE REAR OF CABIN. DETERMINED CAUSE TO BE BURNED CONNECTIONS AT THE AUX CABIN HEATER, DEACTIVATED AUX CABIN HEATING SYSTEM AND VERIFIEDUNDER FLOOR HEATER OPERATES NORMALLY IAW MEL 21-9. REMOVED AND REPLACED MELTED TERMINAL LUG ON WIRE H230A8 TO HEATING RELAY K293 IAW WDG 21-40-00. (LWG). REMOVED AND REPLACED AUX CABIN HEATER CONTACTOR P/N:974.09.26.111(ON/OFF), S/N:2249(OFF), S/N:2774(ON) IAW PILATUS WDM 21-40-00. FUNCTION TEST GOOD.(SAR)

DURING A FLIGHT FROM KAPA TO KJAC, THE CREW DIVERTED TO KDEN AFTER A PARK/EMERG BRAKE ON CAS MESSAGE. THE AIRCRAFT LANDED WITHOUT INCIDENT, BUT DID DECLARE AN EMERGENCY. MAINTENANCE TECHNICIANS REMOVED THE PARK/EMERGENCY BRAKE PRESSURE SENSOR P/N 957.12.10.677 S/N 0134 IAW PC24-A-E32-40-0019-00A-520A-A AND INSTALLED A NEW PRESSURE SENSOR P/N 957.12.10.677 S/N 1150 IAW PC24-A-E32-40-0020-00A-720A-A. OPS CHECKS AND LEAK CHECKS WERE SATISFACTORY.

ON DESCENT SELECTED FLAPS TO 8 DEGREES AMBER FLAPS FAIL CAS MESSAGE DISPLAYED FLAPS FAILED AT 3 DEGREES. RAN QRH DID NOT CORRECT. AIRCRAFT DIVERTED TO HLN CREW DID NOT DECLARE AN EMERGENCY HOWEVER ATC REQUESTED EMERGENCY EQUIPMENT. MAINTENANCE TECHNICIANS REPLACED THE RH OUTBOARD FLAP ACTUATOR , PERFORMED RIGGING AND FUNCTIONAL TESTS. ALL CHECKS WERE SATISFACTORY AND THE AIRCRAFT WAS RETURNED TO SERVICE.

THE AIRCRAFT DEPARTED FROM KPBI. DURING DECENT TO TIST, THE CREW REPORTED MULTIPLE CAS MESSAGES IN-FLIGHT, UPON DESCENT, LANDING GEAR WOULDN’T EXTEND DUE TO POPPED ECB, MX FAIL CAS, AND EMERGENCY LANDING GEAR EXTENSION WAS UTILIZED TO SAFELY LAND AIRCRAFT. THE MAINTENANCE CREW REPLACED THE EPDU1 AND PERFORMED ALL OPERATIONAL CHECKS GOOD. THE LANDING GEAR EXTENSION/RETRACTION CHECK WAS GOOD.

AFTER TAKEOFF FROM KBVU ON A FLIGHT TO KRNO, THE CREW REPORTED "NOSE GEAR STUCK DN, GEAR ACTUATTOR CNTRL, AMBER CAS." THE CREW DECIDED TO DECLARE AN EMERGENCY AND LAND AT KHND, AND DID SO SUCCESSFULLY WITHOUT FURTHER INCIDENT. MAINTENANCE TECHNICIANS RESET THE GEAR ACTUATOR CONTROL CAUTION CIRCUIT BREAKER. THE LANDING GEAR EXTENSION AND RETRACTION TEST WAS PERFORMED IAW AMM 12-B-32-30-00-00A-903B-A. THE EMERGENCY EXTENSION TEST WAS PERFORMED IAW AMM 12-B-32-10-00A-903A-A. ALL CHECKS WERE SATISFACTORY.

AFTER TAKEOFF UPON GEAR RETRACTION NOSE GEAR DID NOT INDICATE UP AND LOCKED. THE CREW DIVERTED BACK TO PHX WITH THE LANDING GEAR EXTENDED IN THE DOWN AND LOCKED POSITION. WE ARE CURRENTLY WAITING ON MAINTENANCE SUPPORT. TECH SIGN OFF STATED THAT NLG FAILED TO INDICATE UP. DISCOVERED NLG STRUT NOT FULLY EXTENDING. REBUILT NOSE STRUT IAW CMM 32-20-05, ALL LEAK AND OPERATIONAL CHECKS SATISFACTORY.

CREW HAD SMOKE COMING OUT OF THE VENTS ON THE LEFT SIDE WHERE THE PIC SITS. THE CREW SHUT OFF THE ACS AND THE SMOKE STOPPED. THEY HAD 2 CAS MESSAGES COME ON, PITOT HEAD STRUT HTR STBY AND PITOT STRUT HTR STBY WITH THE ASSOCIATED ECBS TRIPPED. ECB TRIP IN FLIGHT. THE CREW DECIDED TO DIVERT FROM KRME TO KALB. THE CREW DID NOT DECLARE AN EMERGENCY. TECHNICIANS REPLACED THE STANDBY PITOT STATIC PROBE WITH A NEW PROBE IAW AMM PC24-A-E34-11-0003-00A-720A-A AND THE PROBE PLUG CONNECTOR IAW WDM PC24-A-E30-39-2310-00A-051A-A. LEAK AND OPS CHECKS GOOD.

AFTER TAKEOFF, THE CREW REPORTED THAT THE LANDING GEAR WOULD NOT RETRACT. THE CREW DECIDED TO LAND AT THE ORIGINAL DEPARTED AIRPORT WITH NO FURTHER INCIDENT. TECHNICIANS FOUND THE LANDING GEAR POWER CB ON THE CO-PILOTS JUNCTION BOX TO NOT BE FULLY SEATED. AFTER RESEATING THE CB, C/W GEAR SWING OPS CHECK IAW PILATUS AMM-12-B-32-30-00-00A-903B-A. NO DEFECTS NOTED.

ON APPROACH TO PBI, THE CREW RECEIVED LEFT GEAR UNSAFE INDICATION WITH GEAR MISMATCH CAS. AFTER CYCLING GEAR AND SETTING FLAPS TO 15, INDICATIONS EXTINGUISHED, AND THE LANDING WAS UNEVENTFUL. TECHNICIANS EMBODIED SB 32-018 TO SOLVE THIS ISSUE, AND PERFORMED A SATISFACTORY LANDING GEAR OPERATION TEST.

IN CRUISE FLIGHT THE CREW SAW THE OIL TEMP START TO CLIMB AND THEY RECEIVED A RED OIL TEMP CAS MESSAGE. CREW FOLLOWED QRH, & OIL TEMP DROP MOMENTARILY BUT SPIKED AGAIN. DECLARED AN EMERGENCY & LANDED AT THEIR SCHEDULED DESTINATION AIRPORT, BFI. CREW REPORTED THE AIRPORT ROLLED FIRE EQUIP. TECH FOUND OIL LEVEL NORMAL & A FAILED SPLICE AT OIL TEMP SENSOR. OIL INDICATION FOUND TO FLUCTUATE ERRATICALLY WHEN SPLICE WAS MOVED. TECH PERFORMED A REPAIR OF THE TWISTED PAIR E9A-24 IAW PC-12/47E WDM 79-30-00 & AMM 12-B-20-20-10-00A-040A-A. ENGINE OPS FOR 5 MINUTES & PERFORMED AN OIL TEMP SENSOR CHECK IAW 12-B-79-30-03-00A-920A-A, NO FURTHER DEFECTS.

AFTER DEPARTING PDK THE CREW RECEIVED MULTIPLE CAS MESSAGES, AP 1&2 FAIL, TF 1&2 FAIL, FD 1&2 FAIL, AOC UPLINK FAIL, AND AT FAIL. THE CREW DECIDED TO RETURN TO PDK. TECHNICIANS FOUND AHRS VERTICAL SPEED INERTIAL RATE OUT OF TOLERANCE AT -57.0 FT/MIN. THEY REMOVED A FAULTY AHRS AH-1000 P/N HG2205AB03 S/N 56139126 AND INSTALLED A NEW UNIT P/N HG2205AB03 S/N 56220998 IAW AMM PC-24-A-E34-21-0001-00A-720A-A. ALL OPERATIONAL CHECKS GOOD.

DURING TAKEOFF FROM KPSM, CREW REPORTED NLG WHEEL IND GAVE GEAR IN TRANSIT WARNING WITH HANDLE UP. CREW LANDED AT KPSM WITHOUT INCIDENT. TROUBLESHOOTING & REPAIR IS ONGOING. THE NOSE LANDING GEAR STRUT WAS REBUILT WITH NEW SEALS, A NEW STEERING TUBE P/N 532.20.12.120, AND NEW BARREL NUT P/N 532.20.12.242 DUE TO CORROSION. THE UPPER TORQUE LINK P/N 532.20.12.131 WAS BENT BY MAINTENANCE, AND WAS ALSO REPLACED. WORK PERFORMED IAW CMM-32-20-05. NLG STRUT REMOVED AND INSTALLED IAW PILATUS AMM 12-B-32-20-01-00A-920B-A. ALL FUNCTIONAL CHECKS SATISFACTORY AND AIRCRAFT RETURNED TO SERVICE.

AFTER DEPARTURE FROM KEGE TO KIFP, THE CREW NOTICED HYDRAULIC FLUID COMING FROM UNDER THECENTER PEDESTAL AND SOAKING INTO THE CARPET. THE CREW DIVERTED TO KAPA AND ATC DECLARED ANEMERGENCY ON BEHALF OF THE CREW. ON LANDING THEY ALSO SAW HYDRAULIC FLUID IN THE NLG BAY. TECHNICIANS REMOVED AND REPLACED THE LANDING GEAR SELECTOR VALVE, P/N ON/OFF 960.30.01.274, S/N OFF 0769C, S/N ON 0825C IAW AMM 12-B-32-30-03-00A-902A-A, LEAK AND OPERATIONAL TESTS PERFORMED SATISFACTORY.

DURING CRUISE FROM DEPARTING AIRPORT KACK ON A FLIGHT TO KBKL, THE CREW OBSERVED FLUCTUATING FUEL FLOW INDICATIONS OF 10-20 POUNDS PER HOUR EVERY 4-5 SECONDS. ALL OTHER ENGINE INSTRUMENTS FLUCTUATED ACCORDING WITH THE INCREASE AND DECREASE OF FUEL FLOW. THE CREW DIVERTED TO KIPT AND LANDED SAFELY WITH NO INCIDENT. TECHNICIANS ARE CURRENTLY SCHEDULED TO TROUBLESHOOT ON 09/13/23. A SUPPLEMENTAL SDR WILL BE FILED WHEN FURTHER INFORMATION BECOMES AVAILABLE.

HE CREW DEPARTED FROM KAVL AND WAS IN CRUISE TO KFXE WHEN THEY RECEIVED A FLAP FAIL CAS MESSAGE WITH THE FLAPS AT THE ZERO DEGREE POSITION. THE CREW DIVERTED TO KFLL. ATC HAD DECLARED AN EMERGENCY, AND THE CREW LANDED WITHOUT ISSUE. TECHNICIANS TROUBLESHOT THE FLAP SYSTEM AND REPLACED THE APCM P/N ON/OFF 960.10.04.201 S/N OFF 9-0118, S/N ON 9-0133 IAW PILATUS AMM PC24-A-E27-50-0007-00A-520A-A AND PC24-A-E27-50-0007-00A-720A-A. THEY ALSO REPLACED THE RH OUTBOARD FLAP ACTUATOR P/N ON/OFF 960.10.04.196, S/N OFF 0024, S/N ON 0035 IAW PILATUS AMM PC24-A-E27-50-0002-03A-520A-A AND PC24-A-E27-50-0002-03A-520A-A. ALL OPERATION CHECKS GOOD. AIRCRAFT IS RETURNED TO SERVICE.

DURING TAKEOFF FROM K6B9 TO KHVN, FLIGHT CREW REPORTED "AFTER TAKEOFF POWER APPLIED, SCREAMING SOUND AND BURNING SMELL BELOW COPILOT FEET. NOISE AND SMELL STOPPED AFTER POWER REDUCED." THE CREW COMPLETED THE FLIGHT WITH NO FURTHER ISSUES. TECHNICIANS INSPECTED THE ACM TURBINE AND FOUND NO ISSUES, PERFORMED A GROUND RUN TEST IAW AMM 12-B-71-00-00-00A-903A-A AND FOUND NO DEFECTS. DURING TEST 18 IAW AMM 12-B-71-00-00A-903S-A, TECHNICIANS FOUND NO CHANGE-OVER FROM P3 TO P2.5. THE AIRCRAFT WAS REPAIRED BY REPLACING THE HP SHUT OFF VALVE WITH A REPAIRED UNIT P/N OFF/ON 2943A000, S/N OFF 1741, S/N ON 1812 IAW AMM 12-B-21-40-04-00A-920A-A. SUBSEQUENT GROUND RUN TESTED GOOD WITH NO DEFECTS.

AFTER TAKEOFF FROM KPSM, THE CREW REPORTED "LANDING GEAR LH MAIN, FAILED TO RETRACT AFTER T.O." THE CREW SAFELY DIVERTED BACK TO KPSM WITHOUT INCIDENT. MAINTENANCE TECHNICIANS DOWNLOADED ACMF AND FHDB FILES IAW PILATUS AMM PC24-A-E45-45-0000-00A-551A-A AND SENT TO PILATUS TECH SUPPORT. THEY ALSO PERFORMED LANDING GEAR EXTENSION AND RETRACTION OPS TEST IAW PILATUS AMM PC24-A-E32-30-0000-00A-320A-A. DURING GEAR SWINGS LH MLG DID NOT RETRACT AT ALL, RH MLG AND NLG RETRACTED FULLY. THE INDICATIONS SHOWED RH MLG AND NOSE UP AND LH MLG DOWN AND GREEN. USED ELDG TEST BOX TO MANUALLY RETRACT THE LH MLG AND THE ACTUATOR WOULD NOT MOVE. A LH MLG ACTUATOR IS CURRENTLY ON ORDER TO FINALIZE THIS REPAIR. A SUPPLEMENTAL SDR WILL BE SUBMITTED WHEN THE REPAIR IS COMPLETE.

AFTER DEPARTURE FROM KJQF AND DURING CRUISE TO KIPT, THE CREW REPORTED "FIRE DETECT CAS MESSAGE IN FLIGHT NO ENGINE FIRE INDICATIONS." THE CREW PERFORMED AN UNSCHEDULED LANDING AT KRDU WITHOUT INCIDENT. A MAINTENANCE TECHNICIAN DISCOVERED A TRIPPED CIRCUIT BREAKER. AFTER RESETTING THE BREAKER AND PERFORMING AN OPERATIONAL CHECK IAW PILATUS AMM 12-B-26-10-00-00A-903A-A, THERE WERE NO FURTHER DEFECTS NOTED.

THE FLIGHT CREW DEPARTED KIXA WITH A DESTINATION OF KPBI. DURING CLIMB, THE FLIGHT CREW REPORTED SMOKE IN COCKPIT COMING FROM GASPER VENT ON PILOT'S SIDE. ALSO NOTED AN ECB TRIP CYAN CAS STBY PS HEAT FAIL AMBER CAS. FILES WERE DOWNLOADED AND SENT TO PILATUS. MECH NOTED A BURNT CONNECTOR & PINS ON THE STANDBY PITOT PROBE. REPLACED WITH NEW THE STANDBY PITOT STATIC PROBE, THE PROBE CONNECTOR HR1211P AND 90* BACKSHELL IAW WDM PC24-A-E30-39-2310-00A-051A-A, AND AMMS PC24-A-E34-11-0003-00A-520A-A, PC24-A-E34-11-0003-00A-720A-A. OPS CHECKS WERE GOOD AND NO FURTHER DEFECTS WERE NOTED.

DURING CLIMB OUT FROM KPSM, THE CREW REPORTED THAT THE LANDING GEAR DID NOT RETRACT. THERE WAS A THREE GREEN INDICATION OF GEAR DOWN-AND-LOCKED. THE CREW RETURNED TO THE AIRPORT AND LANDED WITHOUT INCIDENT. NO EMERGENCY WAS DECLARED. TECHNICIANS CONDUCTED CHECK OF CIRCUIT BREAKER FOUND THE LANDING GEAR CIRCUIT BREAKER OUT DURING INITIAL INSPECTION. PERFORMED EXTENSION AND RETRACTION TEST IAW PILATUS AMM 12-B-32-30-00-00A-903B-A NO FAULTS FOUND. EXTENDED AND RETRACTED GEAR SEVERAL MORE TIMES WITH NO DEFECTS NOTED.

DURING FLIGHT FROM KPSM TO KACK, THE CREW REPORTED A YELLOW CAUTION MESSAGE, "MAIN BRAKE FAIL." THE CREW DIVERTED BACK TO KPSM AND LANDED WITHOUT INCIDENT. TECHNICIANS DOWNLOADED ACMF AND FHDB FILES TO SEND TO PILATUS FOR ANALYSIS IAW PILATUS AMM PC24-A-E45-45-0000-00A-551A-A AND SERVICED HYDRAULIC FLUID IAW PILATUS AMM-PC24-A-A12-20-0005-00A-212A-A. PILATUS TECHNICAL SUPPORT REQUESTED BRAKE SYSTEM TEST 11 IAW PILATUS AMM-PC24-A-E32-40-0000-00A-340A-A, IF CHECKS GOOD THEN MONITOR AIRCRAFT AFTER RETURN TO SERVICE. TECHNICIANS PERFORMED TEST 11 IAW PILATUS AMM-PC24-A-E32-40-0000-00A-340A-A. NO DEFECTS NOTED.

ACFT CLIMBING OUT OF 15-16,000 FT WHEN CREW HEARD A LOUD BANG & EXPERIENCED VIBRATION WITH NOTICED A SIGNIFICANT LOSS OF THRUST FROM RT ENG, FOLLOWED BY A BRIEF HIGH ITT INDICATION & BRIEF SMOKY ODOR, WITH R FADEC FAIL & R OIL PRESS LOW CAUTION MESSAGES. A LARGE AMOUNT OF YAW & CREW DECLARED AN EMERGENCY. ABLE TO GET TURNED AROUND & BACK SAFELY TO TEB WITHIN 10 MINS. AFTER ENG SHUTDOWN ON GROUND, CREW REPORTED A R OIL CHIP CAUTION MESSAGE. ON INSPECT NOTED AFT STAGE TURBINE BLADE MISSING. DOWNLOADED FADEC FILES. REMOVED ENGINE IAW AMM PC24-A-E72-00-0000-00A-520A-A AND PC24-A-E72-00-0000-00A-530A-B AND FJ44-4A-QPM LMM 72-00-00. INSTALLED A NEW ENG IAW AMM PC24-A-E72-00-0000-00A-710A-B, PC24-A-E72-00-0000-00.

DURING A ROUTINE FLIGHT FROM KBOX TO KCYUL, THE FLIGHT CREW NOTED A PROP DE-ICE FAIL CAS IN FLIGHT. THE CREW DECLARED AN EMERGENCY AND DIVERTED TO KCYUL. THE AIRCRAFT CONTINUED TO LAND WITHOUT INCIDENT. REPLACED THE LEAD TO THE PROP DE ICE SYS.

DURING FLIGHT FROM KBOS TO KAVL, THE FLIGHT CREW REPORTED LOUD GRINDING SOUND AND BURNING SMELL FROM COCKPIT OUTLETS. THE FLIGHT CREW DIVERTED TO KTEB, DID NOT DECLARE AN EMERGENCY, AND LANDED WITHOUT INCIDENT. REMOVED COCKPIT EVAPORATOR IAW PAMM PC24-A-E21-80-0001-00A-520A-A AND INSTALLED A REPAIRED COCKPIT EVAPORATOR P/N 959.90.20.307 S/N 1-C60861-1 IAW PILATUS AMM PC24-A-E21-80-0001-00A-720A-A, OPERATIONAL CHECKS GOOD.

DURING A PRELIMINARY INSPECTION PRIOR TO A SCHEDULED INSPECTION, THE AIRCRAFT WAS FOUND TO HAVE HAIL DAMAGE TO THE LEFT AND RIGHT WINGS, AILERONS, FLAPS, HORIZONTAL STABILIZERS, AND ELEVATORS. AILERONS AND ELEVATORS WERE DENTED BEYOND SRM LIMITS IAW SRM 12-B-57-60-00-00A-661A-A AND 12-B-55-00-00-00A-661B-A. AILERONS WERE REPLACED WITH NEW UNITS IAW TM-12-006009 AND AMM 12-B-57-60-02-00A-920A-A. ELEVATORS WERE REPLACED WITH REPAIRED UNITS IAW AMM 12-B-55-20-01-00A-920A-A. PILATUS ENGINEERING IS CURRENTLY ASSESSING THE DAMAGE TO THE WINGS, HORIZONTAL STABILIZERS, AND FLAP STRUCTURES TO DETERMINE APPLICABLE REPAIRS IAW SRM 12-B-51-10-04-00A-661A-A. ORIG SUBMISSION DATE: 1-6-2023.

PROBLEM: DURING A FLIGHT FROM KILG TO KPSM THE FLIGHT CREW ENCOUNTERED "SMOKE IN COCKPIT/CABIN, DISSIPATED AFTER SECURING CABIN HEAT." THEY DECLARED AN EMERGENCY AND DIVERTED TO KPNE, LANDING WITHOUT INCIDENT. RESOLUTION: THE FLIGHT CREW DISCREPANCY " SMOKE IN THE CABIN" WAS CALLED TO THE AIRCRAFT AND WORKED BY OUTSTATION MAINTENANCE. THE FOLLOWING WAS COMPLETED TO RETURN THE AIRCRAFT TO SERVICE. " “REMOVED AND REPLACED LH CABIN HEATERS P/N 959.90.20.405, REMOVED LH FWD HEATER S/N 1-F772310-1, INSTALLED NEW HEATER S/N P009450-3,REMOVED LH AFT HEATER S/N 1-B274467-1,INSTALLED SERVICEABLE HEATER 1-G757150-1 IAW AMM PC24-A-E21-40-0002-00A-520A-A AND PC24-A-E21-40-0002-00A-720A-A OPS CHECK GOOD NO FURTHER DEFECTS NOTED"

DURING FLIGHT FROM KGAI TO KGRR THE FLIGHT CREW REPORTED "STRONG ELECTRICAL BURNING SMELL NOTED IN FLIGHT." THE FLIGHT CONTINUED AND THE AIRCRAFT LANDED WITHOUT INCIDENT. RESOLUTION: ? REMOVED AND REPLACED LH AFT CABIN HEATER WITH NEW UNIT IAW PC-24 DM PC24-A-E21-40-0002-00A-520A-A AND PC24-A-E21-40-0002-00A-720A-A. OPERATIONAL CHECK GOOD. P/N OFF: 959.90.20.405 S/N OFF: 1-A98734-3 / P/N ON: 959.90.20.405 S/N ON: P008478-2.