SUNSET AVIATION LLC

DURING A RECENT LANDING GEAR INSPECTION AT STANDARD AERO VNY IT WAS NOTED THAT BOTH LH AND RH AXLES WERE MISSING BUSHINGS FOR STRUT ATTACH PINS TO AXLES, RESULTING IN DAMAGE REQUIRING REPLACEMENT OF BOTH AXLES AND THE RH STRUT PISTON SPHERICAL BEARING. BOTH AXLES HAD BEEN REPLACED BY GAL-FARNBORUGH IN SEPTEMBER 2022 UNDER GAL WORK ORDER SC23024. AIRCRAFT HOURS AUG 2022 - 6611, AIRCRAFT CYCLES AUG 2587

PILOT REPORTED: 10 MINUTES BEFORE DESCENT "L REV UNLOCK" MSG WITH WEIRD PUMP WINDING NOISE. "HYD COMB FAIL" MSG ALSO 10 MINUTES LATER LOST ALSO AUX SYS. PRESSURE AND QTY LOST - LANDED FLAPS - NO ANTI-SKID - EMERG BRAKE.

DURING AN INSPECTION THE RUDDER TRAVEL WAS NOTED TO BE BEYOND LIMITS. FURTHER INVESTIGATION FOUND THE RUDDER IDLER LEVER ASSEMBLY PART NUMBER GC413-2340-1 , WHICH HAD BEEN REMOVED TO FACILITATE MAINTENANCE AND REINSTALLED DURING THIS VISIT WAS IMPROPERLY MARKED “UP AND DOWN” MARKINGS WERE INVERTED ON THE PART DURING MANUFACTURING. THIS LED TO INCORRECT RUDDER DEFLECTIONS AS ONE LEG OF THE IDLER LEVER IS LONGER THAN THE OTHER. RUDDER IDLER LEVER MEASUREMENTS WERE TAKEN AND SENT TO BOMBARDIER ENGINEERING AND THEY CONFIRMED PART WAS INCORRECTLY MARKED BASED ON THE ARM DIMENSIONS.

"AFT COMPT" FIRE WARNING BEGAN INTERMITTENTLY FOLLOWED BY REPETITIVE AND CONTINUOUS WARNING. PERFORMED EMERGENCY PROCEDURE AS PER MANUFACTURER CODDE 3 CHECKLIST. DECLARED EMERGENCY WITH ATC AND PROCEEDED TO DIVERT TO THE NEAREST SUITABLE AIRPORT (EINN). EMERGENCY PROCEDURES DID NOT RESOLVE THE APPARENT FIRE AND THE WARNING PERSISTED FOR THE REMAINDER OF THE FLIGHT UNTIL DECENT. UPON LANDING ARFF PERFORMED VISUAL AND HEAT TRACING INSPECTION WITH NO FINDINGS.

DURING MAINTENANCE FOUND THE IDG WIRE HARNESS CHAFED ON IDG FEEDER CABLE ANCHOR PLATE. SEVERAL WIRES CHAFED ON NR 2 ENGINE HARNESS AND LOWER COWL DOOR HARNESS.

AIRCRAFT RELEASED PARKING BRAKE TO TAXI ONTO RUNWAY. AIRCRAFT NEEDED MORE POWER THAN USUAL TO START TAXI. HALFWAY THROUGH TURN ONTO RUNWAY, LOUD BANG WAS HEARD BY CREW, THEN AIRCRAFT ROLLED EASIER. CREW REQUESTED TAXI FROM ACTIVE, THEN RETURN TO RAMP. AFTER SHUTDOWN, THE RIGHT MAIN INBOARD TIRE WAS FOUND BLOWN, AND THE RIGHT INBOARD BRAKE LINE WAS DISCONNECTED FROM THE BRAKE BODY AT THE QUICK DISCONNECT. IT WAS DETERMINED THAT THE BRAKE LINE QUICK DISCONNECT FAILED AND POPPED OFF WHEN THE PARKING BRAKE WAS SET, CAUSING THE BRAKE TO LOCK WITH NO MEANS TO UNLOCK.

DURING A 12M/800 HRS INSPECTION, THE PITCH AFU WAS FOUND INSTALLED UPSIDE DOWN. THE AMM TASK CARD 27-35-05-900-801 REMOVAL/INSTALLATION OF THE PITCH MAIN AFU INCLUDES A SPECIFIC WARNING TO PREVENT THIS INCORRECT INSTALLATION: THE PITCH MAIN AFU (524CW) IS INSTALLED WITH ITS ADJUSTABLE END-FITTING FACING DOWN. THIS INCORRECT INSTALLATION DOES NOT CAUSE ANY OPERATING PROBLEMS. IT CAUSES A SLIGHT RISK OF INTERFERENCE WITH THE CONTROL ROD BEHIND THE AFU (NO INTERFERENCE NOTED ON THIS AIRCRAFT). AS THE LAST MAINTENANCE ON THIS EQUIPMENT WAS NOT PERFORMED BY DFS, WE CANNOT ESTABLISH THE ROOT CAUSES WITH CERTAINTY. THE PITCH MAIN AFU WILL BE REINSTALLED IN ITS CORRECT POSITION, ADJUSTMENTS, AND TESTS WILL BE PERFORMED, AS PER AMM 27-35-05-900-801.

THE SUPPLY CABLE AND POSITIVE TERMINAL ON THE LT WINDSHIELD DEICING POWER SUPPLY, L1001DG, PN16N24334 HAD BEEN SEVERELY HEAT DAMAGED. THE THREE DEICING POWER SUPPLIES WERE REPLACED FOR AN UPGRADE ON 23 MARCH 2017. REMOVE AND REPLACED DAMAGED POWER SUPPLY. REMOVED AND REPLACED DAMAGED POWER SUPPLY CABLE. WHEN INSPECTING THE GROUND AND POWER CONNECTIONS ON THE RT WINDSHIELD AND BACK UP DEICING POWER SUPPLIES, THE NEGATIVE POST CONNECTION ON THE BACKUP POWER SUPPLY HAD THE LOCKING WASHER SERRATED FACE INSTALLED BACKWARDS. WASHER WAS REPOSITIONED TO THE CORRECT ORIENTATION. NO FURTHER DEFECTS NOTED.

SUSPECTED TIRE SEPARATION ON DEPARTURE. DAMAGED LT MAIN DOOR, WOW WIRE HARNESS & FLAP SKIN. ONLY COCKPIT INDICATION WAS OTBD ANTI-SKID FAIL CASS MSG ON APPROACH.

ON DEPARTURE, RECEIVED THE, NO TAKEOFF, CALL OUT AT 80 KNOTS & ABORTED THE TAKEOFF ROLL. ON THE PDU THE OTBD SLAT PORTION SHOWED RED. DURING THE TROUBLESHOOTING THE TECHNICIANS NOTICED THAT WHEN THE SLATS WERE DEPLOYED THE LT OTBD SLAT COULD BE MOVED SLIGHTLY CAUSING THE RED INDICATION ON THE PDU. DISCOVERED ONE OF THE BOLTS FOR THE SLAT SWITCH STOP PLATE WAS MISSING. INSPECTED THE SURROUNDING AREA & FOUND NO DAMAGE. INSTALLED THE MISSING BOLT & THE ACFT WAS RELEASED. THE AREA THIS IS LOCATED IN IS NOT ABLE TO BE SEEN EASILY DURING THE COURSE OF ROUTINE MX.

AIRCRAFT DEPARTED AFTER SCHEDULED MX & FLEW TO HOME BASE. WHILE PERFORMING THE POST FLIGHT WALK AROUND THE TECHNICIAN NOTICED THE CTR BELLY FUEL BAY DOOR WAS MISSING & HAD DEPARTED THE ACFT IN FLIGHT. NO UNUSUAL SENSATIONS WERE NOTED DURING THE FLIGHT. NO DECLARATIONS WERE MADE & NO ALTERNATE PROCEDURES WERE INITIATED. NO FURTHER DAMAGE WAS NOTED ON THE ACFT.

AIRCRAFT WAS ON ITS 2ND LEG OF THE DAY ENROUTE. THE LANDING GEAR DID NOT DEPLOY WHEN SELECTED GEAR DOWN. DURING INVESTIGATION IT WAS DETERMINED THE RADOME HAD MOVED AFT ALLOWING THE AFT PORTION TO COVER THE FRONT LIP OF THE NOSE LANDING GEAR DOORS PREVENTING THEM FROM OPENING. THE STOPS ON THE RADOME WERE ADJUSTED INCORRECTLY.

DURING POSTFLIGHT INSPECTION, FOUND AFT CABIN VIP SEAT SWITCHING PANEL ASSY, LOCATED ON DRINK RAIL, TO BE INOPERATIVE AND COULD SMELL ODOR CAUSED BY AN INTERNAL SHORT TO THE SWITCHING PANEL ASSY. THE SWITCHING PANEL IS NOT THERMALLY PROTECTED AND THE ELECTRICAL SHORT CONTINUED UNTIL POWER WAS REMOVED. THE SWITCH PANEL ASSY WAS "HOT" TO TOUCH, HAD TO WAIT FOR IT TO COOL DOWN BEFORE IT COULD BE REMOVED FOR REPAIR. UPON FURTHER INVESTIGATION, FOUND THAT THE SHORT WAS CAUSED BY AN INTERNAL SCREW THAT HAD CHAFED THRU THE POWER HARNESS. THIS COULD HAVE BEEN PREVENTED HAD THE POWER HARNESS BEEN PROTECTED BY APPLYING ANTI-CHAFE MATERIAL OVER SCREW HEADS. UNIT WAS SENT AND WAS REPAIRED UNDER WO 327-9073 ON MARCH 18, 2015.

SMOKE IN THE GALLEY. SUSPECTED NR 3 IRU FAN. OPEN

DURING AN 800 HOUR INSPECTION, WHILE PERFORMING THE INSPECTION TASK 32-34-00-720-801 "FUNCTIONAL TEST OF THE LANDING GEAR EMERGENCY-EXTENSION SYSTEM", STEP 2.D.4 "VISUAL CHECK OF THE MLG UPLOCKS, A CRACKED SUPPORT INTERCOSTAL WAS FOUND IN THE RIGHT HAND MAIN LANDING GEAR WHEEL WELL. THE CRACK WAS ALONG THE AFT FLANGE OF THE INTERCOSTAL AND WAS APPROXIMATELY 2.5 INCHES IN LENGTH. THE CRACKED INTERCOSTAL WAS REPLACED PART FOR PART.

RT WING TRAILING EDGE INBOARD PANEL ADJACENT TO FUSELAGE (WS 48.30) HAS A CRACK 1.25 INCH LONG AND HAD THREE SCREWS PULLED THROUGH.

GALLEY DRAIN INOPERATIVE AT SINK AND COFFEE MAKER. FOUND HEATED DRAIN LINE IS NOT HEATING UP.

DURING POST FLIGHT, FOUND CMC INOPERATIVE ON CO-PILOTS MFDU. FOUND FILE SERVER 2 AFSEM 2 FAULTED. PERFORMED TARGET LOAD OF SOFTWARE LOAD 20 AND SYS CHECKED GOOD.

COPILOT'S SEAT WAS REMOVED FOR RECOVERING. DURING THE RECOVERING IT WAS NOTICED THAT THE SEAT HEIGHT ADJUSTMENT TORQUE TUBE WAS CRACKED. THE TECHNICIANS WORKING ON THE SEAT ADVISED THAT THIS IS NOT AN UNCOMMON FAILURE.

DPI FOUND EXTENDED DURING PF INSPECTION. REMOVED FILTER AND FOUND MINOR METAL IN FILTER AND FILTER HOUSING. REPLACE RT HYDRAULIC ENGINE DRIVEN PUMP.

DPI FOUND EXTENDED DURING INITIAL 100 HOUR INSPECTION. REMOVED FILTER AND FOUND METAL IN FILTER AND FILTER HOUSING. REPLACE RT HYDRAULIC ENGINE DRIVEN PUMP.