N208US

Part: LANDING GEAR — MALFUNCTIONED · airframe 62,160 hrs · 58,145 cycles

DURING APPROACH, GEAR HANDLE PLACED IN DOWN POSITION. NOSE LANDING GEAR LIGHT DID NOT ILLUMINATE GREEN. CYCLED GEAR, NOSE GEAR LIGHT STILL DID NOT ILLUMINATE GREEN. DECLARED EMERGENCY AND RAN COM EMERGENCY GEAR EXTENSION PROCEDURE. NOSE GEAR LIGHT STILL DID NOT ILLUMINATE GREEN. UNABLE TO VISUALLY VERIFY THROUGH EMERGENCY NOSE GEAR LATCH PEEP HOLE. ON SHORT FINAL LIGHT FINALLY ILLUMINATED GREEN. ACFT LANDED WITHOUT FURTHER INCIDENT. ACFT WAS FLOWN UNDER A SPECIAL FLIGHT PERMIT WITH THE GEAR DOWN AND LOCKED. MAINTENANCE AT INSPECTED NLG DOWN LOCKED, GREEN LIGHT, LIGHT SOCKET, FOUND NO DEFECTS. INSPECTED NLG DOWNLOCK SWITCH, CLEANED CONNECTOR PLUG, OPS CHECK WAS GOOD. NLG DOWN LOCKED INDICATOR OPS CHECKED GOOD. SWUNG GEAR SEVERAL TIME AND NO DEFECTS NOTED. CLEANED NLG DOWNLOCK VIEWER AND REAPPLIED RED PAINT TO NLG DOWNLOCK INDICATOR ON GEAR. ALL GEARS OPERATE NORMALLY DURING OPS CHECK. ALL WORK DONE IAW MM 32-60-00 AND 32-30-00, NO DEFECTS NOTED. ACFT WAS RETURNED TO SERVICE.

Part: LINE — FAILED (NR 1 ENGINE OIL) · airframe 61,043 hrs · 57,339 cycles

CREW REPORTED POST V1 & JUST INTO ROTATION, MASTER CAUTION ILLUMINATED FOR LT OIL PRESSURE LOW. DECISION MADE TO LEAVE MLG DOWN. OIL PRESSURE LOW & QTY DECREASING, NORMAL CHECKLIST COMPLETED & ABNORMAL CHECKLIST LEADING TO A PRECAUTIONARY SHUTDOWN. CREW ELECTED TO CONTINUE WITHOUT SHUTTING DOWN ENGINE. LANDED WITHOUT INCIDENT. NR 1 ENGINE SHUTDOWN PERFORMED ON GROUND. FOUND NR 1 ENGINE OIL LINE BETWEEN OIL COOLER & TOP OF GEARBOX HAD SEPARATED CAUSING LOSS OF OIL PRESSURE & QUANTITY. ENGINE REMOVED & REPLACED. INSPECTION OF OIL LINE REVEALED FERULE ON END OF LINE HAD COME LOOSE ALLOWING LINE TO SEPARATE. OIL LINE APPEARS TO HAVE BEEN SPRUNG (DISTORTED).

Part: TEE FITTING — CORRODED (ZONE 200) · corrosion level 2 · airframe 61,042 hrs · 57,337 cycles

DURING C-CHECK INSPECTION, MX DISCOVERED A TEE FITTING CORRODED AT BS 160 ON THE RT CUSP LINE. MX R & R TEE FITTING IAW SRM 51-30-2 AND 51-30-5.

Part: PANEL — DELAMINATED (ZONE 500) · airframe 61,042 hrs · 57,337 cycles

DURING C-CHECK INSPECTION, MX DISCOVERED THE INBD LT T/E WING PANEL DELAMINATED. MX R & R PANEL WITH SERVICEABLE IAW SRM 51-30-2.

Part: LONGERON — CORRODED (ZONE 100) · corrosion level 2 · airframe 61,042 hrs · 57,337 cycles

DURING C-CHECK INSPECTION, MX DISCOVERED LONGERON END SHOVEL CORRODED IN THE LOWER AFT CARGO BAY AT BS 996 ON LONGERONS 29L. MX R & R SHOVELS IAW SRM 51-30-5.

Part: SLEEVE — CRACKED (STAB HINGE) · airframe 61,042 hrs · 57,337 cycles

DURING C-CHECK INSPECTION, MX DISCOVERED BOTH LT AND RT HORIZONTAL STABILIZER HINGE BOLT SLEEVES CRACKED. MX R & R SLEEVES IAW AMM 55-10-0.

Part: WINDOW FRAME — CRACKED (COCKPIT) · airframe 61,042 hrs · 57,337 cycles

DURING INSPECTION IAW AD 2002-21-09, 2 EACH .5" CRACKS WERE DISCOVERED IN THE CENTER FRAME OF THE COCKPIT WINDOW SILL. MX R & R THE COCKPIT WINDOW SILL CENTER FRAME WITH NEW IAW SB 53-290 R3, DWG SR09530268, SRM 51-30-2 AND 51-30-5.

Part: PANEL — DELAMINATED (ZONE 500) · airframe 61,042 hrs · 57,337 cycles

DURING C-CHECK INSPECTION, MX DISCOVERED THE SECOND FROM OTBD LT T/E WING PANEL DELAMINATED. MX R & R PANEL WITH SERVICEABLE IAW SRM 51-30-2.

Part: SKIN — CORRODED (ZONE 100) · corrosion level 2 · airframe 61,042 hrs · 57,337 cycles

DURING C-CHECK INSPECTION, MX DISCOVERED THE LOWER AFT CARGO BAY SKIN CORRODED AT BS 756, LONGERON 27L 29R. MX REPAIRED IAW EA 13-53-321 AND DER DWG 53-13118-1, 8110-3, DATED 3/19/13.

Part: BRACKET — CORRODED (ZONE 200) · corrosion level 2 · airframe 61,042 hrs · 57,337 cycles

DURING C-CHECK INSPECTION, MX DISCOVERED THE MAIN UPPER CARGO DOOR LOWER SILL BRACKET CORRODED. MX R & R BRACKET IAW SRM 51-30-5.

Part: SPAR — CRACKED (LT ELEVATOR) · airframe 61,042 hrs · 57,337 cycles

DURING C-CHECK X-RAY INSPECTION, MX DISCOVERED THE LT ELEVATOR FRONT SPAR CRACKED OUT OF LIMITS. MX AT YIP R & R THE LT ELEVATOR WITH A SERVICEABLE PART IAW MM 27-30-2.

Part: HINGE — CRACKED (LT WING TE FLAP) · airframe 61,042 hrs · 57,337 cycles

DURING C-CHECK INSPECTION, MX DISCOVERED THE LT WING CENTER AFT FLAP HINGE CRACKED. MX R & R HINGE IAW AMM 27-51-1 AND OHM 27-50-1.

Part: WEB — CORRODED (ZONE 100) · corrosion level 2 · airframe 61,042 hrs · 57,337 cycles

DURING C-CHECK INSPECTION, MX DISCOVERED THE LOWER AFT CARGO BAY CENTERLINE WEB CORRODED AT BS 996. MX REPAIRED IAW SRM 53-01, FIG 2 SHEET 3 AND EA 96-51-02 R3.

Part: SKIN — CRACKED (LT WING TE FLAP) · airframe 61,042 hrs · 57,337 cycles

DURING C-CHECK INSPECTION AT YIP, MX DISCOVERED THE LT FLAP LOWER SKIN CRACKED. MX AT REPAIRED IAW SRM 57-01, FIGURE 3, SHEET 2 AND EA 96-51-02 R1.

Part: BATTERY PACK — DISCHARGED (EMERGENCY LIGHTS) · airframe 59,986 hrs · 56,560 cycles

EMERGENCY LIGHTS INOPERATIVE DURING INSP. MX R & R BATTERY POWER SUPPLY IAW AMM 33-50-0. OPS CHECKS GOOD, NO OTHER DEFECTS NOTED.

Part: DOWNLOCK SWITCH — MALFUNCTIONED (ZONE 700) · airframe 59,273 hrs · 56,007 cycles

UPON APPROACH, THE RT MLG DID NOT DISPLAY GREEN INDICATION, ONLY RED. CREW EXECUTED MISSED APPROACH AND REVIEWED COM PROCEDURES. CREW DIVERTED AND DECLARED AN EMERGENCY INBOUND. CREW FOLLOWED COM PROCEDURES FOR MANUAL EXTENSION OF GEAR AND SECONDARY SYS SHOWED A GREEN LIGHT BUT RED LIGHT REMAINED ILLUMINATED. THE GEAR WARNING HORN WAS SILENCED BY PULLING THE GEAR WARNING HORN CIRCUIT BREAKER. THE ACFT LANDED WITHOUT FURTHER INCIDENT, STOPPED ON RUNWAY AND A CREW MEMBER PINNED THE RT GEAR. THE ACFT WAS SUBSEQUENTLY FLOWN UNDER SPECIAL FLIGHT PERMIT BACK TO MAIN BASE. MX R & R THE RT MLG DOWNLOCK SWITCH IAW MM 32-30-0. THE OPS CHECK WAS GOOD. MX ALSO REPLACED THE LT MLG DOWNLOCK PROXIMITY SWITCH IAW MM 32-30-0. THE OPS CHECK WAS GOOD AND THE ACFT WAS RETURNED TO SERVICE AFTER GEAR SWINGS.

Part: RIB — CRACKED (VERTICAL STAB) · airframe 57,322 hrs · 54,679 cycles

RIB CRACKED AT FASTENER LEFT SIDE OF VERTICAL STAB LEADING EDGE XFS 148. REPAIRED IAW DC9 SSRM DWG K05159.

Part: RIB — CRACKED (VERTICAL STAB) · airframe 57,322 hrs · 54,679 cycles

RIB CRACKED AT FASTENERS LEFT AND RIGHT SIDES OF VERT STAB LEADING EDGE ZFS 18. REPAIRED IAW DC9 SSRM DWG K05159.

Part: RIB — CRACKED (VERTICAL STAB) · airframe 57,322 hrs · 54,679 cycles

RIB CRACKED AT FASTENERS LEFT AND RIGHT SIDES OF VERT STAB LEADING EDGE ZFS 50. REPAIRED IAW DC9 SSRM DWG K05159.

Part: RIB — CRACKED (VERTICAL STAB) · airframe 57,322 hrs · 54,679 cycles

RIB CRACKED AT FASTENERS LEFT AND RIGHT VERT STAB LEADING EDGE ZFS 43. REPAIRED IAW DC9 SSRM DWG K05159.

Part: RIB — CRACKED (VERTICAL STAB) · airframe 57,322 hrs · 54,679 cycles

RIB CRACKED AT FASTENER LEFT SIDE VERT STABILIZER LEADING EDGE ZFS 93. REPAIRED RIB IAW DC9 SRM D05159.

Part: RIB — CRACKED (VERTICAL STAB) · airframe 57,322 hrs · 54,679 cycles

RIB CRACKED AT FASTENER RIGHT SIDE OF VERTICAL STAB LEADING EDGE ZFS 80. REPAIRED RIB IAW DC9 SSRM K05159.

Part: RIB — CRACKED (VERTICAL STAB) · airframe 57,322 hrs · 54,679 cycles

RIB CRACKED AT FASTENERS LEFT AND RIGHT SIDES OF VERTICAL STAB LEADING EDGE ZFS 74. REPAIRED LEFT AND RIGHT RIBS IAW DC9 SSRM K05159.

Part: RIB — CRACKED (VERTICAL STAB) · airframe 57,322 hrs · 54,679 cycles

RIB CRACKED AT FASTENERS LEFT AND RIGHT SIDES OF VERTICAL STAB LEADING EDGE ZFS 50. REPAIRED IAW DC9 SSRM DWG K05159.

Part: RIB — CRACKED (VERTICAL STAB) · airframe 57,322 hrs · 54,679 cycles

RIB CRACKED AT FASTENERS LEFT AND RIGHT SIDES OF VERTICAL STAB LEADING EDGE ZFS 18. REPAIRED IAW DC9 SSRM DWG K05159.

Part: RIB — CRACKED (VERTICAL STAB) · airframe 57,322 hrs · 54,679 cycles

RIB CRACKED AT FASTENERS LEFT AND RIGHT SIDE OF VERTICAL STAB LEADING EDGE ZFS 43. REPAIRED IAW DC9 SSRM DWG K05159.

Part: RIB — CRACKED (VERTICAL STAB) · airframe 57,322 hrs · 54,679 cycles

RIB CRACKED AT FASTENER RIGHT SIDE OF VERTICAL STAB LEADING EDGE ZFS 23. REPAIRED IAW DC9 SSRM DWG K05159.

Part: RIB — CRACKED (VERTICAL STAB) · airframe 57,322 hrs · 54,679 cycles

RIB CRACKED AT FASTENERS LEFT AND RIGHT SIDES OF VERT STAB LEADING EDGE ZFS 18. REPAIRED IAW DC9 SSRM DWG K05159.

Part: DOUBLER — CRACKED (FUSELAGE) · airframe 57,322 hrs · 54,679 cycles

DOUBLER SKIN BETWEEN STA 1132 AND 1143 WAS CRACKED AT BOTH CORNERS TO FASTENER HOLES. INSTALLED TWO DOUBLERS AT EACH CRACK LOCATION IAW DC9 SRM 53-01 FIG 2, SHEET 3.

Part: FRAME — CRACKED (FUSELAGE) · airframe 57,322 hrs · 54,679 cycles

FRAME AT STA 1168 AT APPROX 3 O'CLOCK POSITION WAS CRACKED. REPAIRED AREA IAW DC9 SRM 53-01, FIG 2.

Part: REPAIR — DAMAGED (AFT CARGO DOOR) · airframe 57,322 hrs · 54,679 cycles

AFT LOWER CARGO DOOR INNER PAN REPAIR AT THE AFT LOCK REQUIRED EVAL IAW AD 2006-10-14. REMOVED AND REPAIRED AREA IAW DC9 SRM 52-05, FIG 26B, 51-30-5, 51-30-2, AND ST-6244-03.

Part: FRAME — CRACKED (FUSELAGE) · airframe 57,322 hrs · 54,679 cycles

FRAME CRACKED STA 1076, LONGERON 14 RIGHT. REPAIRED FRAME IAW DC9 SRM 53-03, FIG 32, SHEET 4.

Part: DOOR — CRACKED (RT MLG WW) · airframe 57,322 hrs · 54,679 cycles

RIGHT MAIN LANDING GEAR INBOARD DOOR CRACKED, UPPER AFT CORNER. REPAIRED CRACKED AREA IAW DC9 REA D952-57026.

Part: STRUCTURE — CRACKED (FUSELAGE) · airframe 57,322 hrs · 54,679 cycles

STRUCTURE UNDER FORWARD LOWER CARGO DOOR AFT ATTACH POINT AS SEEN THROUGH LIGHTENING HOLE WAS CRACKED. REPAIRED IAW REA D953-57015-MR.

Part: FRAME — CORRODED (FUSELAGE) · airframe 47,322 hrs · 54,679 cycles

FRAME CORRODED ON AFT SIDE AT STA 350, LONGERON 30. REPAIRED CRACKED FRAME IAW DC9 SRM 53-03.

Part: RIB — CRACKED (LT HORIZ STAB) · airframe 57,322 hrs · 54,679 cycles

LEFT HORIZONTAL STAB LEADING EDGE NR 3 FROM INBOARD RIB CRACKED. INSTALLED SINGLE STACK REPAIR IAW DC9 ABX DWG K05159.

Part: SUPPORT — CRACKED (RT SPOILER) · airframe 57,322 hrs · 54,679 cycles

RIGHT INBOARD SPOILER TORQUE TUBE INBOARD VERTICAL SUPPORT CRACKED AT UPPER END. REMOVED AND REPLACED SUPPORT IAW DC9 SRM 51-30-1, 51-30-2 AND 51-30-5.

Part: SKIN — CORRODED (LT WING) · airframe 57,322 hrs · 54,679 cycles

LEFT WING UPPER TRAILING EDGE SKIN BULGED, RIVETS CUPPED FORWARD OF SPOILER BOARDS (CENTER). CUT OUT DAMAGE. INSTALLED NEW SECTION OF SKIN AND -9 DOUBLER IAW DC9 SRM 57-30-3, 57-01, FIG 3, 51-30-2 AND 51-30-5.

Part: CSD — FAILED (NR 2 ENGINE) · airframe 57,180 hrs · 54,570 cycles

CREW REPORTED ENGINE VIBRATION THEN FAILURE ON NR 2 ENGINE. IRREGULARITY FILLED OUT BY CREW REPORTED AS FOLLOWS. AFTER DEPARTURE IN CLIMB, VIBRATION FOLLOWED BY NR 2 ENGINE FLAME OUT AT FL190 FOLLOWED BY AIRCRAFT CROSSTIE LOCKOUT. CREW DECLARED AN EMERGENCY AND RETURNED TO POINT OF DEPARTURE AT MMCU. AIRCRAFT MADE AN UNEVENTFUL LANDING AT MMCU. AFTER AIRCRAFT LANDED MAINTENANCE WAS SENT TO MMCU TO INSPECT ENGINE AND AIRCRAFT. USA JET MECHANIC PERFORMED A VISUAL INSPECTION ON THE ENGINE AND FOUND NO DEFECTS IN THE INLET OR EXHAUST. THE MECHANIC FOUND DURING TROUBLING SHOOTING THE NR 2 CSD/GENERATOR HAD FAILED. THE ON-SITE MECHANIC PULLED , INSPECTED AND REPLACED WITH NEW THE NR 2 ENGINE OIL FILTER WITH NO DEFECTS FOUND IN THE FILTER. THE CSD/GEN WAS DISCONNECTED AND DEFERRED IAW MEL 24-1, DMI NR 0098 INCLUDING SP 24-1. THE AC CROSSTIE WAS OP'S CHECKED IAW DC-9 MM WITH NO DEFECTS NOTED. THE AIRCRAFT THEN HAD A COMPLETE GROUND RUN PERFORMED WITH NO VIBRATION OR ADVERSE INDICATIONS FOUND. THE AIRCRAFT WAS RETUNED TO SERVICE AT THIS TIME. MAINTENANCE AT USA JET HOME BASE HAS REPLACED THE CSD/GEN, CSD OIL COOLER AND PERFORMED REQUIRED GROUND RUNS TO CLEAR DMI NR 0098, ALL MAINTENANCE WAS COMPLETED IAW DC-9 MAINTENANCE MANUALS.

Part: RELAY — FAILED (APU)

CREW WORKING ELECTRICAL PROBLEM ON LT BUSS USING COM W/APU STARTED & RUNNING. APU LOW OIL PRESSURE LIGHT & OIL TEMP HIGH LIGHT ILLUM. APU SHUTDOWN. A/C OPS ON NR 2 GEN & BATTERIES. AN EMERGENCY DECLARED, A/C GIVEN DIRECT TO SDF & VECTORED FOR APPROACH. AIRCRAFT LANDED WITHOUT FURTHER INCIDENT AT SDF. NR 2 GENERATOR REMAINED OPERABLE DURING DESCENT AND LANDING. MANTENANCE DISPATCHED TO SDF FOUND THE APU OIL REQUIRED SERVICING. APU OIL WAS SERVICED AND THE SYSTEM THEN CHECKED GOOD IAW DC-9 MM 49-10-0. LT GENERATOR SYS THEN OPERATIONALLY CHECKED GOOD IAW THE DC-9 MM 24-20-6. THE AIRCRAFT WAS RETURNED TO SERVICE. (M)