N205US

Part: SENSOR — FAILED (MLG LATCH) · airframe 26,370 hrs · 13,935 cycles

CREW REPORTED DURING GEAR RETRACTION, LEFT GEAR UNSAFE LIGHT REMAINED ILLUMINATED. PERFORMED COM PROCEDURE, DECLARED EMERGENCY, REMAINED AIRBORNE TO BURN OFF FUEL TO MEET LANDING WEIGHT REQUIREMENTS. LANDING GEAR EXTENDED NORMALLY. COMPLETED UNEVENTFUL LANDING. INSTALLED A NEW SERVICEABLE LEFT MAIN GEAR LATCH SENSOR IAW MM 32-60-1. TESTED GOOD AND PERFORMED GEAR SWING TO FURTHER TEST. NO DEFECTS NOTED. AIRCRAFT WAS SUBSEQUENTLY TEST FLOWN SATISFACTORILY.

Part: WARNING SYSTEM — MALFUNCTIONED · airframe 25,715 hrs · 13,586 cycles

IMMEDIATELY AFTER TAKEOFF, COULD SMELL AN ELECTRICAL BURNING ODOR FOLLOWED BY A MASTER CAUTION LIGHT. SEVERAL ANNUNCIATORS CAME ON AND OFF, FOLLOWED BY THE GPWS FAIL, STALL INDICATION FAIL AND FLAP/RUDDER/STOP INOPERATIVE REMAINING ON. IMMEDIATELY STARTED A TURN TO STAY IN PATTERN WHILE ATC INFORMED OF OUR INTENTION TO RETURN BECAUSE OF THE ORDER. IMMEDIATELY CLEARED TO LAND. UPON ARRIVING BACK ON THE RAMP THE LEFT GENERATOR OFF LIGHT CAME ON. USA JET MAINTENANCE FOUND FAINT SMELL OF SMOKE IN #2 INSTRUMENT AMP. REMOVED AND REPLACED NR 2 INSTRUMENT AMP, NR 2 PITCH STEERING AND NR 2 ROLL STEERING COMPUTER. FOUND GREEN LIGHT OF STALL COMPUTER INOPERATIVE. REMOVED AND REPLACED #2 STALL COMPUTER. LEFT GENERATOR SHOWED NO FREQS OR VOLTS. REMOVED AND REPLACED LEFT ENGINE GENERATOR CONTROL UNIT IAW MM 24-20-00, 24-20-7 & 71-00. OPERATIONAL CHECK WAS GOOD. SUSPECT GENERATOR SWITCHING TO APU POWER CAUSE OF GPWS FAIL, STALL INDICATION FAIL, AND RUDDER/STOP INOPERATIVE. TESTED EGPWS. NO FAULT HISTORY FROM LAST FLIGHT. SYSTEM CHECKED GOOD IAW MM. RUDDER STOP OPERATIONALLY CHECKS GOOD IAW MM 27-20-14. NR 1 AND 2 STALL SYSTEM CHECK GOOD IAW MM 24-14-0. NR 2 FLIGHT DIRECTOR SYSTEM CHECKS BAD FOR RUNWAY FLAG. FLIGHT DIRECTOR BOXES REPLACED IAW MM 34-14-0. REMOVED AND REPLACED #2 ADI AND RADIO ALTIMETER TRANSCEIVER IAW MM 34-25-00 AND 34-37-00. REMOVED AND REPLACED NR 1 INSTRUMENT AMP IAW MM 34-25-00. SYSTEM OPERATIONALLY CHECKS GOOD IAW MM 34-25-00 AND 34-31-0. REMOVED ECM PANELS AND PERFORMED A GENERAL VISUAL INSPECTION. NO DEFECTS NOTED. INSPECTED 110 JUNCTION AND 110 RELAY PANEL. INSPECTED E&E BAY FOR DAMAGE. NO DEFECTS NOTED. RAN AIRCRAFT IN MULTIPLE CONFIGURATIONS IAW MM 71-00 WITH NO DEFECTS NOTED. AIRCRAFT WAS SUBSEQUENTLY TEST FLOWN TO CONFIRM REPAIRS. FLIGHT CREW REPORTED THE TEST FLIGHT AS SATISFACTORY. AIRCRAFT WAS RETURNED TO SERVICE.

Part: SKIN — CORRODED (BS 570-595) · corrosion level 2 · airframe 25,211 hrs · 13,313 cycles

MAINTENANCE DISCOVERED A MISSING RIVET FROM THE BELLY SKIN AT FS 585. UPON FURTHER INSPECTION, IT WAS DETERMINED THAT THERE WAS INTERNAL AND EXTERNAL CORROSION AND A TEMPORARY REPAIR WAS INSTALLED AND THE AIRCRAFT WAS FERRIED FOR REPAIR. MAINTENANCE INSTALLED PERMANENT REPAIR FROM FS 570 TO FS 595 BETWEEN L28L AND L28R IAW FORM 8110-3, NR 15454 AND DWG 53-15453-1.

Part: ATTACH ANGLE — CRACKED (RT NACELLE) · airframe 22,915 hrs · 11,937 cycles

EMERGENCY PROCEDURE, UNSCHEDULED LANDING, EMERGENCY DESCENT. RT PYLON UPPER PYLON TO FUSELAGE ATTACH ANGLE 12, AFT OF LEADING EDGE HAS 1 CRACK AT CORNER, DISCOVERED DURING C-CHECK INSPECTION. MX REPAIRED IAW SRM 54-04, FIG 10.

Part: SKIN — CHAFED (VERTICAL STAB) · airframe 22,915 hrs · 11,937 cycles

EVIDENCE OF DAMAGE ON UPPER RT SIDE OF VERTICAL STABILIZER BETWEEN STATION ZV120 NEAR FORWARD END OF UPPER AND LOWER BODY FAIRINGS, DISCOVERED DURING C-CHECK. MX REPAIRED IAW DWG 55301301-1 AND APPROVED 8110-3 DATED 02/19/13.

Part: SKIN — CRACKED (BS 950 L14-15R) · airframe 22,915 hrs · 11,937 cycles

EMERGENCY PROCEDURE, EMERGENCY DESCENT, UNSCHEDULED LANDING. FUSELAGE SKIN CRACKED AT BS 950 BETWEEN L14-15R, DISCOVERED DURING C-CHECK INSPECTION. MX REPAIRED IAW SRM 54-04, FIG 46.

Part: SHEAR TIE — CRACKED (BS 945) · airframe 22,915 hrs · 11,937 cycles

UNSCHEDULED LANDING, EMERGENCY DESCENT, ETC. SHEAR TIE CRACKED AT BS 945 BETWEEN LONGERONS 14R AND 17R, DISCOVERED DURING C-CHECK INSPECTION. MX REPLACED SHEAR TIE IAW SRM 51-30-5.

Part: FITTING — CRACKED (LT NACELLE) · airframe 22,915 hrs · 11,937 cycles

UNSCHEDULED LANDING, EMERGENCY DESCENT, ETC. LT PYLON REAR SPAR UPPER CAP FITTING AT STATION 1038 FOUND CRACKED DURING C-CHECK INSPECTION. MX REPLACED FITTING IAW SRM 51-30-1, 51-30-3 AND 51-30-5.

Part: FITTING — CRACKED (RT NACELLE) · airframe 22,915 hrs · 11,937 cycles

UNSCHEDULED LANDING, EMERGENCY DESCENT. RT PYLON REAR SPAR UPPER CAP FITTING AT STATION Y 1038 FOUND CRACKED DURING C-CHECK INSPECTION. MX REPLACED FITTING IAW SRM 51-30-1, 51-30-3 AND 51-30-5.

Part: TURBINE BLADES — DAMAGED (NR 1 ENGINE) · airframe 22,675 hrs · 11,779 cycles

CREW REPORTED AFTER DEPARTURE WHEN TRANSITIONING TO QUIET EPR POWER SETTING A SUDDEN LOUD AND EXTREME VIBRATION OCCURRED. OBSERVED LOSS OF EPR, N1 & N2. LT ENGINE WAS VERIFIED AS FAILING AND SOURCE OF VIBRATION WITH THROTTLE TO IDLE. EMERGENCY DECLARED AND NR 1 ENGINE SHUTDOWN DUE TO WORSENING VIBRATION. ACFT MADE A NORMAL LANDING WITHOUT INCIDENT. ENGINE FOUND SEVERELY DAMAGED TURBINE BLADES. NO DAMAGE FOUND TO INLET, FAN AND COMPRESSOR. NR 1 ENGINE REPLACED.

Part: FITTING — CRACKED (LT PYLON) · airframe 19,108 hrs · 9,739 cycles

PYLON UPPER REAR SPAR STRAP CLIP JUST INSIDE PYLON CRACKED. REMOVED, FABRICATED, AND INSTALLED NEW CLIP IAW DC9 SRM 51-30-1 AND 51-30-5.

Part: ATTACH ANGLE — CRACKED (FUSELAGE) · airframe 19,108 hrs · 9,739 cycles

ATTACH ANGLE FOR STA 41 TO STA 69 PRESSURE PANEL INTERCOSTAL CRACKED. SECOND INTERCOSTAL TO THE LEFT OF THE PLUG DOOR. REMOVED AND REPLACED IAW DC9 SRM 51-30-5.

Part: ATTACH ANGLE — CRACKED (FUSELAGE) · airframe 19,108 hrs · 9,739 cycles

ATTACH ANGLE FOR STA 41 TO STA 69 PRESSURE PANEL INTERCOSTAL CRACKED JUST RIGHT OF PLUG DOOR. REMOVED AND REPLACED ANGLES IAW DC9 SRM 51-30-5.

Part: ATTACH ANGLE — CRACKED (KEEL WEB) · airframe 19,108 hrs · 9,739 cycles

LEFT WHEEL WELL KEEL WEB UPPER ATTACH ANGLE AT STA 718 CRACKED. REMOVED AND REPLACED FITTING IAW DC9 SRM 51-30-1 AND 51-30-5.

Part: ATTACH ANGLE — CRACKED (RT MLG WW) · airframe 19,108 hrs · 9,739 cycles

INBOARD BULKHEAD STA 718 ATTACH ANGLE CRACKED. REMOVED AND REPLACED FITTING IAW DC9 SRM 51-30-5.

Part: SKIN — CRACKED (AFT CARGO DOOR) · airframe 19,108 hrs · 9,739 cycles

FORWARD LOWER CARGO DOOR SKIN CRACKED AT DOOR HANDLE. REPAIRED AND PAINTED IAW DC9 SRM 25-05 AND 51-10.

Part: SKIN — CRACKED (AFT CARGO DOOR) · airframe 19,108 hrs · 9,739 cycles

AFT LOWER CARGO DOOR SKIN CRACKED AT DOOR HANDLE. REPAIRED DOOR IAW DC9 SRM 52-05, FIGURE 30, SHEET 1.

Part: PROXIMITY SWITCH — OUT OF RIG (MLG)

YIP - UPON CLIMB-OUT AFTER TAKEOFF, GEAR DOWN LIGHT WOUDLD NOT EXTINGUISH. CREW PERFORMED PROCEDURE 2-32-6 IAW COM. CREW REQUESTED FIRE EQUIP PRIOR TO LANDING. AIRCRAFT LANDED WITHOUT FURTHER INCIDENT AT YIP. MAINTENANCE FOUND THE LEFT GEAR DOOR PROXIMITY SWITCH OUT OF RIG. MAINTENANCE RIGGED SWITCH IAW DC-9 MM 32-60-3. THE AIRCRAFT WAS JACKED AND THE LANDING GEAR WAS CYCLED. THE LANDING GEAR OPERATIONALLY CHECKED GOOD IAW DC-9 MM 32-30-0. NO FURTHER DEFECTS WRE NOTED AND THE AIRCRAFT WAS RELEASED TO SERVICE. (M)