N197US

Part: LINE ASSY — CHAFED (V STAB PITOT)

RUDDER TRAVEL UNRESTRICTED LIGHT CAME ON IN CRUISE FLIGHT. FOUND VERTICAL STABILIZER PITOT STATIC LINE CHAFED THROUGH AND LEAKING AT BULKHEAD. WHEN REMOVING SAME LINE FROM ANOTHER AIRCRAFT IN HEAVY CHECK, FOUND LINE CHAFED IN THE SAME PLACE. (N NR 196US). SEE IPC 34-11-00 FIG 63 ITEM 35. LINES ARE CHAFING WHERE THEY GO THOUGH THE BULKHEAD AT ITEM 100. ITEM 100 IS A RUBBER GROMMET WHICH FAILS ALLOWING LINE TO CHAFE. REPAIRED BY REPLACING LINE AND GROMMET. ALSO ISSUED FLEET CAMPAIGN TO CHECK THESE LINES ON ALL OUR DC9 AIRCRAFT. NO SUBSEQUENT FINDINGS.

Part: HEAT EXCHANGER — MALFUNCTIONED (CABIN COOL SYS)

YIP - UNSCHEDULED LANDING WHEN AIRCRAFT WOULD NOT HOLD CABIN AT 16,000 FEET WITH ONLY LEFT PACK. FLIGHT OFFICER NOTICED LACK OF PRESSURIZATION AT 4,000 FEET. MANUAL PRESSURIZATION APPEARED TO HELP BUT NOT ADEQUATE. AIRCRAFT RETURNED TO POINT OF DEPARTURE AT YIP. THE RIGHT PACK HAD BEEN DEFERRED IAW USA JET MEL ITEM 21-1. REPAIRED NUMEROUS LEAKS IN THE CABIN PRESSURE VESSEL AND ADJUSTED OUTFLOW VALVE, IAW DC9 MM 21-34-0, SYSTEM OPS CHECK GOOD. REMOVED AND REPLACED RIGHT PRIMARY AND SECONDARY HEAT HEAT EXCHANGERS IAW DC9 MM 21-51-5. SYSTEM OPS CHECK GOOD. (M)

Part: SKIN — CRACKED (BS 108)

YIP - FOUND ONE SMALL CRACK IN THE LEFT SIDE OF THE NOSE LANDING GEAR WHEEL WELL SKIN AT STATION 108. REMOVED DAMAGED SKIN AREA. FABRICATED AND INSTALLED REPAIR FILLER AND REPAIR DOUBLER PER USA JET AIRLINES ENGINEERING AUTHORIZATION NR 96-53-02R1. (M)

Part: GEAR BOX — OIL LEAK (NR 2 ENG)

DFW - SHUT DOWN RIGHT ENGINE DUE TO LOW OIL PRESSURE AND QUANTITY. INSPECTED AND FOUND ENGINE GEARBOX LEAKING AT SCAVENGE PORT. REMOVED AND REPLACED GEARBOX. (M)

Part: FAN GUIDE VANE — CRACKED (NR 1 ENGINE)

YIP - FLIGHT CREW REPORTED LIGHT ENGINE VIBRATION EN ROUTE TO YIP. UPON LANDING, ENGINE WAS INSPECTED AND A 30-INCH CRACK WAS DETECTED IN THE LEFT ENGINE LOWER FAN EXIT GUIDE VANE CASE. CRACK WAS IN THE FORWARD RADIUS OF THE CASE AND RAN DOWN FROM THE TOP OF THE LOWER CASE SECTION IN A VERTICAL DIRECTION ALONG THE RADIUS. REMOVED AND REPLACED FAN EXIT GUIDE VANE. PERFORMED ENGINE VIBRATION MONITORING PERFORMANCE ENGINE RUN AND CONDUCTED A TEST FLIGHT OF THE AIRCRAFT. (X)

Part: SHEAR CLIP — CORRODED (FS 860)

YIP - FOUND CORRODED SHEAR CLIP DURING SCHEDULED MAINTENANCE. FABRICATED NEW SHEAR CLIP, HEAT TREATED TO T-6 CONDITION PER MIL-H-6088F AND INSTALLED NEW SHEAR CLIP. PART TC: 46,789. (X)

Part: ACT BELLOWS — LEAKING (RUDDER CONTROL)

DFW - UNSCHEDULED LANDING AT DFW FOR RUDDER TRAVEL UNRESTRICTED LIGHT ILLUMINATED AT CRUISE. DRAINED ACCUMULATED FLUID FROM SYSTEM SUMPS, OPS CHECK GOOD AS PER MM 27-20-3. (M)

Part: GEAR HANDLE — MALFUNCTIONED (LANDING GEAR)

DFW - ON FINAL APPROACH INTO DFW, GEAR HANDLE WOULD NOT GO DOWN, AFTER SEVERAL ATTEMPTS THE GEAR HANDLE DID GO DOWN AND THE GEAR EXTENDED NORMALLY. PERFORMED GEAR RETRACTION AND EXTENSION, OPS CHECKS GOOD PER DC-9 MM 32-30-0, NO DEFECTS NOTED. (M)

Part: HYD LINE — BROKEN (RT MLG WW)

MCI - LOST ALL HYDRAULIC FLUID FROM RIGHT SYSTEM AND SUBSEQUENT PRESSURE. FURTHER INVESTIGATION SHOWED A HYDRAULIC LINE FAILURE IN THE RIGHT WHEEL WELL. REMOVED AND REPLACED LINE WITH A SERVICEABLE UNIT. (M)

Part: GEARBOX — FAILED (LT ENGINE)

OIL LEAK DISCOVERED ON THE LEFT ENGINE (S/N 657238) AFTER LANDING IN YIP. FURTHER INVESTIGATION REVEALED FOUR BROKEN STUBS IN THE MAIN ENGINE GEARBOX HOUSING. THE GEAR BOX WAS REMOVED AND REPLACED. (M)

Part: CONTROL CABLE — BROKEN (RT TE FLAP VANE)

YIP - AIRPLANE HAS A RYTHMATIC VIBRATION AT ALL SPEEDS, BUT MORE PRONOUNCED AT LOW ALTITUDES. INSPECTED AND FOUND RIGHT MOVEABLE VANE CABLE FOUND TO BE BROKEN (CABLE RUN NR 169A, P/N 3922841-561). REMOVED AND REPLACED BROKEN CABLE. INSPECTED ASSOCIATED EQUIPMENT FOR DAMAGE AND CONDITION, RERIGGED CABLE SYSTEM. (M)

Part: GEARBOX — FAILED (ENGINE)

PIA - SHUT DOWN THE ENGINE. DECLARED AN EMERGENCY WITH CHI CENTER, REQUESTED VECTORS TO THE NEAREST AIRPORT. MADE AND UNSCHEDULED LANDING AT PIA. REPLACED THE MAIN ENGINE ACCESSORY GEAR BOX. (M)

Part: UPLATCH ASSY — BINDING (LT MLG)

YIP - FLT AVR6244 - LEFT GEAR UNSAFE LIGHT WOULD NOT EXTINGUISH AFTER GEAR WAS RETRACTED. AIRCRAFT RETURNED TO YIP. DISASSEMBLED, CLEANED, AND LUBED LEFT MLG UPLATCH ASSY. OPERATIONALLY CHECKED GOOD. (X)

Part: FCU — CONTAMINATED (NR 1 ENGINE)

DTW - ABORTED TAKEOFF. NR 1 ENGINE WOULD NOT REACH TAKEOFF E.P.R. DRAINED F.C.U. MOISTURE TRAP, CLEANED VENT HOLE. ENGINE IS A LOANER, SCHEDULED FOR REMOVAL 6-7-95. ENGINE OWNER NOTIFIED OF CONDITION. REF: OPERATOR CONTROL NR Y2PA95006.

Part: OIL — CONTAMINATED (NR 1 ENGINE)

DTW - ABORTED TAKEOFF. NR 1 ENGINE OIL CLOGGED LIGHT ILLUMINATED. REMOVED OIL FILTER, FOUND CARBON IN FILTER, DRAINED AND RESERVICED OIL TANK. REPLACED FILTER. REF: OPERATOR CONTROL NR 95ZZZX3190. (X)

Part: OIL — CONTAMINATED (NR 1 ENGINE)

DTW - RETURNED TO POINT OF DEPARTURE, DTW. NR 1 ENGINE OIL CLOGGED LIGHT ILLUMINATED (ENGINE SN P-654600). AIRCRAFT ABORTED ON TAKEOFF ROLL. REMOVED OIL FILTER, FOUND CARBON IN FILTER, DRAINED AND RESERVICED OIL TANK. REPLACED FILTER. ENGINE IS A LOANER ENGINE. SCHEDULED FOR REMOVAL ON 6-10-95. ENGINE OWNER NOTIFIED OF CONDITION. (X)

Part: ACT BELLOWS — LEAKING (RUDDER)

YIP - RUDDER UNRESTRICTED ANNUNCIATOR LIGHT VERY SLOW TO COME ON BELOW 170 KNOTS. REMOVED AND REPLACED ACTUATOR BELLOWS (P/N 5914387507) AND 2 EACH ROD END BEARINGS (P/N REP3F4) AND 2 EACH ROD END BEARINGS (P/N 16393). RERIGGED SYSTEM IAW MM 27-20-6. (W)

Part: OIL FILTER — CONTAMINATED (NR 1 ENG)

YIP - RETURNED TO POINT OF DEPARTURE (YIP), NR 1 ENGINE OIL CLOGGED LIGHT ILLUMINATED (ENGINE S/N P-654600). REMOVED OIL FILTER, FOUND CARBON FILTER, DRAINED AND RESERVICED OIL TANK. REPLACED FILTER. (Z)

Part: OIL FILTER — DIRTY (NR 1 ENG)

RETURNED TO YIP, NR 1 ENGINE OIL CLOGGED LIGHT ILLUMINATED. REMOVED OIL FILTER, FOUND CARBON IN FILTER, DRAINED AND RESERVICED OIL TANK. REPLACED FILTER. ENGINE 18.8 HOURS SINCE SHOP VISIT. (Z)

Part: ENGINE — WORN (NR 1)

ELP - DURING CRUISE AT 34,000 FEET, THE CREW ENCOUNTERED A LOUD RUMBLING. ALL SYSTEMS INDICATIONS WERE NORMAL. FURTHER INVESTIGATION REVEALED VIBRATION FROM NR 1 ENGINE WHENEVER POWER WAS ABOVE 1.78 EPR. S/D THE ENGINE WAS REMOVED AND SENT TO BOUNTY MAINTENANCE SERVICES (B4MR567J) FOR TEARDOWN EVALUATION. EXTENSIVE TEARDOWN INSPECTION, AND REPAIR WAS ACCOMPLISHED. NO ITEMS WERE IDENTIFIED THAT WOULD SPECIFICALLY ACCOUNT FOR THE ENGINE VIBRATION, HOWEVER, EXCESSIVE PLAY WAS FOUND IN THE C-1 DISK BLADE AREA, AND TWO WORN BEARINGS WERE NOTED. THE ENGINE WAS RETURNED TO SERVICE AND REINSTALLED ON THIS AIRCRAFT JUNE 23, 1995. (M)