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AIRCRAFT N988NW FALCON 7X S/N 174 DEPARTED SLC RUNWAY 35. ALL NORMAL FROM POWER UP, ACCELERATION, LIFT-OFF. AT GEAR RETRACTION, WE GOT AN CAS MESSAGE “GEAR: RETRACT FAIL” FOLLOWED CLOSELY BY “GEAR: DOOR NOT CLOSED” AND “BRAKE: BOTH SYSTEMS FAIL”. THEY COULD ALSO HEAR AND FEEL THAT THE GEAR DOORS WERE OPEN AND GEAR DOWN AT LEAST TO SOME EXTENT. AIRCREW FOCUSED ON FAULTS AND SOLVING THEM WITH THE AVAILABLE PROCEDURES. AIRCRAFT RETURNED TO SALT LAKE CITY AN AIRCRAFT LANDED NORMALLY. AIRCRAFT WAS PLACED INTO THE MAINTENANCE HANGAR FOR TROUBLESHOOTING. DURING THE TROUBLESHOOTING PROCESS THEY FOUND THAT THE LANDING GEAR AND STEERING CONTROL UNIT TO BE AT FAULT. THE UNIT HAD BEEN CHANGED ON 2/17/2023 AT ACTT: 2898.7 LANDINGS 1267. THE UNIT WAS AN INSPECTED / TESTED UNIT. THE UNIT HAD THE SAME FAULTS THAT THE AIRCRAFT HAD EXPERIENCED. THE MAINTENANCE DEPARTMENT INSTALLED A MODIFIED UNIT AND PERFORMED ALL FUNCTIONAL AND OPERATIONAL CHECKS WITH SATISFACTORY RESULTS.

WHILE PERFORMING WALK AROUND OF AIRCRAFT FOUND RT NLG DOOR ROD END SNAPPED. UPON FURTHER INVESTIGATION FOUND THAT THE RT NLG DOOR CARDAN ASSEMBLY HAD SEIZED CAUSING THE ROD END TO SNAP. DISASSEMBLED, CLEANED, AND LUBRICATIED CARDAN. REMOVED AND REPLACED BROKE ROD END AND PERFORMED LANDING GEAR FUNCTIONAL CHECK, CHECKED SATISFACTORY.

RIGHT WINDSHILED STOPPED HEATING AFTER 45 TO 60 MIN WITH NO CASS MESSAGE OF FAILURE

AFTER TAKEOFF CLEARANCE A CYAN AUTO PILOT FAIL WAS NOTED AND TAKE OFF WAS CANCELLED AND RETURNED TO PARKING.

RED CAS MESSAGE "HIGH OIL PRESSURE" DURING CLIMB AIRCRAFT DIVERTED TO SJC FROM SQL.

NO AIRFLOW COMING FROM COCKPIT GASPERS. TROUBLESHOT TO LEFT EVAPORATOR ASSEMBLY FAN STOPPING INTERMITTENTLY IN FLIGHT. INSTALLED NEW EVAPORATOR ASSEMBLY. OPERATIONAL CHECKED SATISFACTORY.

STICK PUSHER INDICATION WONT CLEAR EVEN AFTER STICK PUSHER TEST. SHAKER WORKS BUT NO PUSHER WHEN DOING THE TEST WITH ENGINE RUNNING. INSTALLED NEW STICK SHAKER SERVO ACTUATOR. OPERATIONAL CHECKED SATISFACTORY.

TAIL DE-ICE DID NOT TEST OR COME ON IN-FLIGHT. TROUBLESHOT AND FOUND NORMAL DE-ICE TIMER TO BE INOPERATIVE.

WHILE ON APPROACH PILOT HAD A LANDING GEAR CONTROL LEVER DISAGREE. GEAR CONTROL LEVER GOES UP HALFWAY IN RETRACTION CYCLE, BUT DOWN ALL THE WAY IN EXTENSION CYCLE. LANDING GEAR CONTROL SELECTOR LEVER ASSEMBLY WAS REMOVED AND A VISUAL INSPECTION OF THE LEVER ASSEMBLY REVEALED THAT A FACE PANEL SCREW THAT WAS INTERNALL TO THE ASSEMBLY HAD CAME OUT AND LODGED BEHIND THE CAM ASSEMBLY CAUSING THE HANDLE TO MALFUNCTION. INSTALLED REPAIRED LANDING GEAR CONTROL LEVER ASSEMBLY. OPERAITONAL CHECKED SATISFACTORY.

THE AIRCRAFT WAS STARTING ITS APPROACH, AND THE AIRCREW RECEIVED A DE-ICE WING/STAB FAIL CAS MESSAGE. AIRCREW TURNED OFF THE WING/TAIL DEICE BEFORE LANDING. AFTER LANDING THE PILOT INSPECTED THE SURFACE DE-ICE BOOTS AND FOUND THAT THE RIGHT WING OUTER DE-ICE BOOT HAD BLOWN,AND A 4 INCH HOLE BLOWN OUT ON THE TOP OUTBOARD PORTION OF THE BOOT.

NR 2 ENGINE SLOW TO START. AIRCRAFT WAS BROUGHT INTO MAINTENANCE. FOUND PUDDLE OF FUEL IN EXHAUST LINER. REMOVED THRUST REVERSER ASSEMBLY AND PERFORMED WET MOTORING OF ENGINE AND DISCOVERED ENGINE FUEL NOZZLE FUEL TUBES AND NOZZLE LEAKING AT 12 O'CLOCK POSITION.

DURING NR 2 ENGINE START, THE STARTER GENERATOR AUTOMATIC CUTOUT FEATURE WHICH IS TO OCCUR AT 60 PERCENT N2 DID WORK. PILOT HAD TO MANUALLY DE-SELECT STARTER GENERATOR FROM OPERATING. REMOVED AND REPLACED THE STARTER GENERATOR. OPS CHECKED SATISFACTORY.

AUTOPILOT FAIL BLUE CAS ACCOMPANIED BY PITCH TRIM CIRCUIT BREAKER OPENED. ONE RESET, OPENED AGAIN, RAN QRH FOR AUTOPILOT FAIL BLUE CAS AND ONE A1 CIRCUIT BREAKER RESET ON GROUND OPENED AGAIN.

PILOT REPORTED THAT THE UNDER FLOOR HEATER TRIPS THE CIRCUIT BREAKER AND WILL NOT RESET. PERFORMED TROUBLESHOOTING OF UNDER FLOOR HEATER SYS. FOUND UNDER FLOOR HEATER K665 CONTACTOR HAD STUCK IN ENERGIZED CLOSED POSITION CAUSING 28 VOLTS TO CONSTANTLY FEED HEATER AND CAUSING MAIN BATTERY DRAW. UPON FURTHER INSPECTION FOUND UNDER FLOOR HEATER HAD SEIZED AND MELTED HEATER FAN TERMINAL F TO GROUND WIRE. REPAIRED WIRING, R & R. K665 RELAY, UNDER FLOOR HEATER AND CONTROLLER. OPS CHECK SATISFACTORY.

WHILE PERFORMING AN AIRCRAFT SERVICE CHECK, FOUND EXTERIOR LOGO LIGHTS INOPERATIVE. PERFORMED TROUBLESHOOTING AND FOUND THAT THE P3 AND J3 PLUG AND CONNECTOR HAD SHORTED AT PIN DD AND MELTED THE PIN AND FEMALE PIN RECEPTACLE. CONNECTOR AND PLUG ARE LOCATED IN LT ELECTRONIC EQUIPMENT RACK, LEER, REF DES 327VB49. P3 AND J3 CONNECTOR AND PLUG ASSY WERE R & R. OPS CHECK OF LOGO LIGHTS WERE SATISFACTORY.

ALTERNATE DE-ICE TIMER FAILED DURING FUNCTIONAL TEST. ORDERED AND INSTALLED REPAIRED ALTERNATE PNEUMATIC TIMER, PN 3D2485-06, SN U1179 UNDER WO SAPO15-49894 DATED 10/15/15. PERFORMED FUNCTIONAL CHECK AND UNIT FAILED FUNCTIONAL CHECK. OUT OF BOX FAILURE, REMOVED PNEUMATIC TIMER AND INSTALLED SERVICEABLE TIMER AND SYS FUNCTIONAL CHECKED SATISFACTORY.

ON THE FLIGHT, HAND FLYING IN CRUISE, ABOUT 9000. WHEN THE YAW TRIM RAN AWAY. ABLE TO INTERRUPT IT AND THEN RETRIM THE ACFT. ABOUT 5 MINUTES LATER IT HAPPENED AGAIN. ONCE AGAIN ABLE TO INTERRUPT IT AND THEN RETRIM IT. AT THIS POINT, DECLARED AN EMERGENCY AND SINCE THE ACFT WAS STABLE AND MOSTLY IN TRIM WE ELECTED TO CONTINUE TO DESTINATION AS WE WERE ALREADY ON THE LOCALIZER.

WHILE PERFORMING THE NR 1 AND NR 2 WHEEL AND TIRE CHANGE. UPON REMOVING THE WHEEL ASSEMBLIES FROM THE ACFT FOUND NR 1 AND NR 2 BRAKE ASSEMBLY CARBON ROTOR ASSEMBLIES TO BE CRACKED AND BROKEN OFF FROM THE KEY WAY GUIDES IN SEVERAL PLACES. R & R NR 1 AND NR 2 BRAKE ASSEMBLIES.

WHILE PERFORMING A SERVICE CHECK ON THE ACFT, NOTICED HYDRAULIC FLUID LEAKING FROM THE LT MLG WHEEL WELL. ON FURTHER INVESTIGATION, FOUND AUXILARY SYS SUCTION LINE LEAKING. REMOVED LINE ASSY AND FOUND 90 DEGREE ELBOW CRACKED. R & R SUCTION LINE AND 90 DEGREE FITTING WITH NEW PARTS. LEAK CHECKED SATISFACTORY.

TWO HOURS INTO FLIGHT, RT ENGINE THROTTLE FROZEN IN PLACE. BECAME LOOSE WHILE HOLDING AT LOWER ALTITUDE. WAS ABLE TO SHUTDOWN ON LANDING. RT FORWARD THROTTLE CABLE, PN 553508-9, SN 0040 WAS REPLACED WITH NEW CABLE.

FOUND RT ENGINE HYD PUMP PRESSURE LINE FROM PUMP TO PYLON CHAFED THRU. CHAFING WAS CAUSED BY ADEL CLAMP SECURING LINE. THE RUBBER AROUND THE CLAMP HAD SLIPPED OFF, CAUSING THE CHAFING.

RIGHT STARTER GENERATOR REQUIRED SEVERAL RESETS DURING LAST TRIP, ON FINAL LEG STARTER/GEN WOULD NOT COME ONLINE. MAINTENANCE PEFORMED VISUAL INSPECTION OF STARTER GENERATOR. FOUND STARTER GENERATOR BRUSHES WORN BEYOND SERVICEABLE LIMITS. STARTER GENRATOR HAD 89.4 HOURS WITH 41 CYCLES SINCE O/H.

ON ENGINE START UP, WHILE PERFORM PRE-TAXI CHECKS, CREW DISCOVERED THE "AC" FAIL LIGHT WAS ILLUMINATED ON THE ANNUNCIATOR PANEL AND WOULD NOT EXTINGUISH. MX PERFORMED TROUBLESHOTTING OF THE SYS AND FOUND THAT THE ANNUCIATOR PANEL WAS THE PROBLEM. THIS WAS THE FIRST FLIGHT WITH NEW ANNUCIATOR PANEL INSTALLED. ANNUCIATOR PANEL WAS R & R WITH REPAIRED ANNUCIATOR PANEL, PN 465-1-17, SN 647. ANNUCIATOR PANEL WAS REPAIRED ON W/O 1865177. OPS CHECKED SATISFACTORY.

VAPOR CYCLE SYSTEM GROUND COOLING FAN DEVELOPED LOUD NOISE AND VIBRATION THAT WAS FELT AND HEARD IN CABIN. MX TROUBLESHOT AND FOUND THAT THE COOLING FAN ASSY HAD COME LOOSE INSIDE OF UNIT AND BANGED AROUND IN CASE. VAPOR CYCLE SYSTEM AND GROUND COOLING FAN INOP. GROUND COOLING FAN, PN 1133710-15, SN 387, REMOVED. INSTALLED MODIFIED GROUND COOLING FAN, PN 1133710-15, SN 398 IAW PHENOM 100 AMM CH 21-23-05. OPS CHECKED SATISFACTORY. GROUND COOLING FAN MODIFIED.

ON AIRCRAFT DEPARTURE THE AIRCREW ATTEMPTED TO RETRACT THE FLAPS. FLAPS DID NOT REPSOND TO THE UP COMMAND. AIRCRAFT RETURNED TO THE AIRPORT, DURING THE APPROACH SELECTED THE FLAPS TO FULL FOR LANDING AND THE FLAPS WENT TO FULL DOWN. AFTER LANDING THE AIRCREW TRIED TO RETRACT THE FLAPS AND AGAIN NO RESPONSE TO THE UP COMMAND. TROUBLESHOT THE SYSTEM AND FOUND THAT THE FLAP UP SWITCH ACTUATOR ARM HAD BROKEN OFF. REMOVED AND REPLACED THE UP AND DOWN FLAP SWITCHES AND ACTUATOR ARMS WITH NEW SWITCHES. OPERATIONAL CHECKED SATISFACTORY.

TROUBLESHOT HYDRAULIC LEAK ON RIGHT ENGINE. FOUND RIGHT HYDRAULIC PRESSURE HOSE FROM ENGINE DRIVEN PUMP TO BE LEAKING FROM PYLON AREA. REMOVED HOSE FOUND HOSE SPLIT. INSTALLED NEW HOSE P/N 624023-6-0246. LEAK AND OPERATIONAL CHECKED SATISFACTORY.

AFT WAS LANDING WHEN A VIOLENT SHIMMY AND VIBRATION OCCURRED BETWEEN 40 TO 50 KTS, EMANATING FROM THE NOSE LANDING GEAR. THE AIRCRAFT WAS BROUGHT INTO MAINTENANCE. FOUND SHIMMY DAMPER LEAKING FLUID. NOSE LANDING GEAR SHIMMY DAMPENER, PN 5543001-11, S/N 684, REMOVED. INSTALLED O/H SHIMMY DAMPENER PN 5543001-12, SN 1123-12X IAW AMM CHAPTER 32-21-02. O/H WO 2-85961 DATED 04/18/12. SEE 8130-3 DATED 04/18/12. OPS CHECKED SATISFACTORY.

DURING A POST FLIGHT INSPECTION, FOUND LT AILERON CRACKED AND DELAMINATED AT THE INBD END CAP OF AILERON. LT AILERON WAS R & R WITH NEW AILERON.

DURING A POST FLIGHT INSPECTION FOUND LT AILERON CRACKED AND DELAMINATED AT THE INBD END CAP OF AILERON. LT AILERON WAS R & R WITH NEW AILERON.

ACFT DEPARTED AT APPROX 1630 ZULU WITH AN INTENDED DESTINATION. WHILE AT CRUISE ALTITUDE RECEIVED AN EICAS MESSAGE INDICATING THE LOSS OF RT HYD PRESSURE. ACFT ELECTED TO DIVERT, AND DURING DESCENT AT ABOUT 30 MINUTES FROM DESTINATION AN ADDITIONAL EICAS MESSAGE INDICATING A LT HYD PUMP FAILURE AND PRESSURE GAUGE READOUT OF ZERO MAIN HYD PRESSURE. AIRCREW CONDUCTED THE APPROPRIATE EMERGENCY CHECKLIST AND DECLARED AN EMERGENCY. APPROX 5 TO 7 MINUTES FROM LANDING, RECEIVED A MESSAGE INDICATING THE LOSS OF AUXILIARY HYD PRESSURE. AIRCREW CONDUCTED EMERGENCY CKLIST AND UPDATED ATC OF THEIR CONDITION. ACFT LANDED WITHOUT INCIDENT. ACFT WAS TOWED TO MFG FOR REPAIR. THEY CHANGED THE RT HYD MAIN RESERVOIR SHUT-OFF VALVE, RT ENGINE DRIVE HYD PUMP, LT ENG DRIVEN HYD PUMP AND AUX HYD PUMP. THE SUSPECTED CAUSE OF HYD FAILURE WAS DETERMINED TO BE THE FAILURE OF THE RT MN HYD SHUT-OFF VALVE NOT OPENING ENOUGH WHICH CAUSED THE HYD PUMPS TO BE STARVED OF HYD FLUID.

(K5SR) WHILE PERFORMING A 500 HR/12 MONTH INSP ON THE LT ENGINE, DISCOVERED THE EMERGENCY FUEL SHUTOFF CABLE HAD UN-TWISTED AT THE CABLE END GOING FROM THE FUEL SHUTOFF VALVE. R & R WITH NEW CABLE ASSY. OPD CKD SATISFACTORY.

NR 1 BRAKE ASSY WORN BEYOND LIMITS AFTER ONLY 19.1 HRS AND 10 CYCLES SINCE O/H UNDER W/O RC1997713.1 DATED 3/22/10. INSTALLED O/H BRAKE ASSY PN 5006575-1, SN MAR03-59, O/H UNDER W.O WP194532/1 DATED APR 13, 2010. OPS CK SATISFACTORY.

NR 2 BRAKE ASSY WORN BEYOND LIMITS AFTER ONLY 19.1 HRS AND 10 CYCLES SINCE O/H UNDER W/O RC1997713.1 DATED 3/22/10. INSTALLED O/H BRAKE ASSY PN 5006575-1, SN MAR03-59, O/H UNDER W.O WP194532/1 DATED APR 13, 2010. OPS CK SATISFACTORY.

WHILE PERFORMING CMP 27301 RUDDER SYS HARD-OVER PREVENTION SYS OPS TEST. FOUND THAT SYS FAILED CHECK. TROUBLESHOOTING THE SYS FOUND CONNECTOR PLUG NR 155A26P3 PIN NR 3 GOING TO RUDDER HARD OVER SWITCHES WAS NOT LOCKED INTO PLUG ASSY. RESECURED PIN NR 3 INTO CONNECTOR PLUG 155A26P3 AND PERFORMED RUDDER HARD-OVER PREVENTION CHECK. WITH SATISFACTORY RESULTS. (K)

RECEIVED NEW WINDSCREEN RT (B) SCREEN PN NH24016-92, SN L366293. WHILE DOING OUR INCOMING PARTS INSPECTION WE DISCOVERED THAT THE TERMINAL BLOCK LAYOUT PLACARD FOR THE WINDOW WAS INCORRECT. IT WAS LAYED OUT FOR THE LT WINDOW ASSY PN NH24016-81 OR NH24016-91. REORDERED ANTOHER WINDSCREEN AND IT HAD THE CORRECT TERMINAL LAYOUT PLACARD. (K)

TRAINING FLIGHT, CFI AND STUDENT ONBOARD. CONDUCTING HOVER AUTOROTATION TRAINING. ON THIRD HOVER AUTOROTATION, AS HELICOPTER SETTLED ON GROUND, STUDENT WAS INPUTTING RT PEDAL TO COMPENSATE FOR LOSS OF TORQUE WHEN A LOUD (SNAP) WAS HEARD FROM THE PILOT SIDE TAIL ROTOR PEDAL AREA. PEDALS BECAME BOUND IN PLACE. SHUTDOWN HELICOPTER AND INSPECTION SHOWED THAT THE BEARING BLOCK SUPPORT FOR THE PILOT SIDE PEDALS HAD BROKEN AND THE SECURING BLOCK WAS NOW FREE AND PEDALS WOULD NOT TRAVEL FREE. (K)

BLOWER INOP.

PRECAUTIONARY SHUTDOWN OF LEFT ENGINE BECAUSE OF INABILITY TO REDUCE POWER FROM CRUISE. SUSPECT MOISTURE IN POWER CONTROL TELEFLEX CABLE ASSEMBLY FREEZING AT HIGH ALTITUDE. (M)