N21CX

Part: FLOORBEAM — CRACKED (FUSELAGE) · airframe 69,635 hrs · 17,928 cycles

DURING ROUTINE C-CHECK INSPECTION A CRACK WAS DETECTED ON THE FLOORBEAM LEFT HAND FRAME ATTACHMENT PLATES AND CLIPS AT FS 320 TO 480. ACCOMPLISHED REMOVAL OF DAMAGED PLATES AND CLIPS. FABRICATED AND INSTALLED NEW ATTACHMENT PLATES AND CLIPS IN ACCORDANCE WITH DOUGLAS STRUCTURAL REPAIR MANUAL AND ENGINEERING ORDER EDP05-1 AND DRAWING NUMBER AE2443.

Part: CLIP — CORRODED (STA 1584) · airframe 69,635 hrs · 17,928 cycles

DURING ROUTINE C-CHECK INSPECTION CORROSION WAS DETECTED IN THE AFT CABIN FLOORBEAM AT STATION 1584. REMOVED DAMAGED FLOORBEAM AND INSTALLED NEW FLOOR SUPPORT AND CLIP NUTS IN ACCORDANCE WITH DOUGLAS STRUCTURAL MAINTENANCE MANUAL.

Part: WING — CRACKED (LEADING EDGE) · airframe 69,635 hrs · 17,928 cycles

DURING ROUTINE C-CHECK INSPECTION, A CRACK WAS DETECTED ON THE RIGHT WING LEADING EDGE AT STATION XW485 JUST OUTBOARD OF THE #4 PYLON. STOP DRILLED CRACK, FABRICATED AND INSTALLED REPAIR DOUBLER IN ACCORDANCE WITH DOUGLAS STRUCTURAL REPAIR MANUAL AND ENGINEERING ORDER EDP05-2

Part: BELT — LOOSE (A/C UNIT) · airframe 68,713 hrs · 17,673 cycles

EN ROUTE FROM KWA TO HIK, AN ODOR WAS SENSED IN THE COCKPIT EMITTING FROM THE COCKPIT AIR CONDITIONING UNIT. THE FLIGHT CREW SECURED THE AIR CONDITIONER AND THE ODOR SUBSIDED. THE FLIGHT CONTINUED TO HIK FOR AN UNEVENTFUL LANDING. MAINTENANCE INSPECTED THE AIR CONDITIONER WHICH REVEALED A LOOSE COMPRESSOR DRIVE BELT AND A CLOGGED DRAIN LINE. MAINTENANCE ADJUSTED THE DRIVE BELT, CLEAR THE DRAIN LINE AND PERFORMED AS SUCCESSFUL OPERATIONAL CHECK IN ACCORDANCE WITH THE COMPANY MAINTENANCE MANUAL. THE AIRCRAFT WAS RETURNED TO SERVICE.

Part: HYDRAULIC LINE — DEFECTIVE (NR 3 ENGINE) · airframe 68,387 hrs · 17,581 cycles

DURING CLIMBOUT FROM AVB, THE FLIGHT CREW NOTICED A DECLINE IN THE MAIN HYDRAULIC QUANTITY AND PRESSURE INDICATION SYSTEMS. THE FLIGHT CREW FOLLOWED COMPANY PROCEDURES AND RETURNED TO AVB FOR AN UNEVENTFUL LANDING. MAINTENANCE INSPECTED THE AIRCRAFT LOCATING A DEFECTIVE HYDRAULIC PRESSURE LINE ON THE NUMBER THREE ENGINE HYDRAULIC PUMP. MAINTENANCE REPLACED THE LINE AND PERFORMED A SUCCESSFUL OPERATIONAL CHECK IN ACCORDANCE WITH THE MAINTENANCE MANUAL. THE AIRCRAFT WAS RETURNED TO SERVICE.

Part: COMPRESSOR — DEFECTIVE (NR 3)

EN ROUTE FROM WRI TO COF, AN ODOR WAS SENSED IN THE COCKPIT ACCOMPANIED BY A LOUD NOISE EMITTING FROM THE NUMBER THREE TURBO COMPRESSOR. THE FLIGHT CREW SECURED THE TURBO COMPRESSOR AND THE ODOR SUBSIDED. MAINTENANCE PLACED THE TURBO COMPRESSOR ON DEFERRAL AND THE AIRCRAFT WAS RETURNED TO SERVICE.

Part: FAN — FAILED (LT COCKPIT)

EN ROUTE FROM AJK TO AVB, THE FLIGHT CREW SENSED AN ODOR IN THE COCKPIT EMITTING FROM THE LEFT RECIRCULATION FAN. THE CREW TURNED OFF THE FAN AND THE ODOR DIMINISHED. MAINTENANCE INSPECTED AND FOUND THE FAN DEFECTIVE. MAINTENANCE DEFERRED THE LEFT RECIRCULATION FAN AND THE AIRCRAFT WAS RETURNED TO SERVICE.

Part: WIRE — LOOSE (LT ALTIMETER)

EN ROUTE, THE FLIGHT CREW DETECTED WHITE SMOKE EMITTING FROM UNDER THE CAPTAIN'S INSTRUMENT PANEL, ACCOMPANIED WITH AN ODOR, THEN DIMINISHED. THE FLIGHT CREW FOLLOWED COMPANY PROCEDURES AND CONTINUED TO KBWI FOR AN UNEVENTFUL LANDING. MAINTENANCE INSPECTED THE CAPTAIN'S INSTRUMENTS AND LIGHTING SYSTEMS WIRING LOCATING A LOOSE WIRE ON THE CAPTAIN'S ALTIMETER VIBRATOR, WHICH WAS SECURED. FURTHER INSPECTION REVEALED NO DISCREPANCIES. MAINTENANCE PERFORMED A SUCCUSSFUL INSTRUMENTATION AND LIGHTING OPERATIONAL TEST ON EXTERNAL AND SHIP'S POWER AND THE AIRCRAFT WAS RETURNED TO SERVICE.

Part: PANEL — CORRODED (LT HORIZ STAB)

DURING ROUTINE C CHECK INSPECTION, CORROSION WAS DETECTED ON LEFT HORIZONTAL STABILIZER UPPER TRAILING EDGE PANEL BETWEEN STATIONS XE 221 AND XE 272. REPAIR ACCOMPLISHED REMOVAL OF DAMAGED AREA, FABRICATION AND INSTALLATION OF A NEW PANEL IN ACCORDANCE WITH FAA DER APPROVED DRAWING F03-R11 AND ENGINEERING ORDER 55-DC8-934.

Part: BULKHEAD DOUBLER — CRACKED (BS 44)

DURING ROUTINE C CHECK INSPECTION, A CRACK WAS DETECTED IN THE LOWER RADOME COMPARTMENT BULKHEAD INNER DOUBLER AT FUSELAGE STATION 44. REPAIR ACCOMPLISHED REMOVAL OF DAMAGED AREA, FABRICATION AND INSTALLATION OF A NEW DOUBLER AND TWO REPAIR SPLICE DOUBLERS IN ACCORDANCE WITH FAA DER APPROVED DRAWING F03-R08 AND ENGINEERING ORDER 53-DC8-931.

Part: PANEL — CORRODED (RT HORIZ STAB)

DURING ROUTINE C CHECK INSPECTION, CORROSION WAS DETECTED ON RIGHT HORIZONTAL STABILIZER UPPER TRAILING EDGE PANEL BETWEEN STATIONS XE 272 AND XE 275. REPAIR ACCOMPLISHED REMOVAL OF DAMAGED AREA, FABRICATION AND INSTALLATION OF A NEW PANEL IN ACCORDANCE WITH FAA DER APPROVED DRAWING F03-R04 AND ENGINEERING ORDER 55-DC8-927.

Part: PANEL — CORRODED (RT HORIZ STAB)

DURING ROUTINE C CHECK INSPECTION, CORROSION WAS DETECTED ON RIGHT HORIZONTAL STABILIZER UPPER TRAILING EDGE PANEL BETWEEN STATIONS XE 149 AND XE 221. REPAIR ACCOMPLISHED REMOVAL OF DAMAGED AREA, FABRICATION AND INSTALLATION OF A NEW PANEL IN ACCORDANCE WITH FAA DER APPROVED DRAWING F03-R03 AND ENGINEERING ORDER 55-DC8-926.

Part: PANEL — CORRODED (RT HORIZ STAB)

DURING ROUTINE C CHECK INSPECTION, A CORROSION BULGE WAS DETECTED ON THE RIGHT HORIZONTAL STABILIZER UPPER TRAILING EDGE PANEL BETWEEN STATION XE 77 AND XE 148. REPAIR ACCOMPLISHED REMOVAL OF DAMAGED AREA, FABRICATION AND INSTALLATION OF A NEW PANEL IN ACCORDANCE WITH FAA DER APPROVED DRAWING F03-R09 AND ENGINEERING ORDER 55-DC8-932.

Part: PANEL — CORRODED (LT HORIZ STAB)

DURING ROUTINE C CHECK INSPECTION, CORROSION WAS DETECTED ON LEFT HORIZONTAL STABILIZER LOWER TRAILING EDGE PANEL BETWEEN STATIONS XE 221 AND XE 272. REPAIR ACCOMPLISHED REMOVAL OF DAMAGED AREA, FABRICATION AND INSTALLATION OF A NEW PANEL IN ACCORDANCE WITH FAA DER APPROVED DRAWING F03-R10 AND ENGINEERING ORDER 55-DC8-933.

Part: PLATING — CORRODED (BS 1500)

DURING ROUTINE C CHECK INSPECTION, A CORROSION BULGE WAS DETECTED ON LOWER FUSELAGE EXTERNAL PLATING AT FUSELAGE STATION 1500 BETWEEN LONGERON 31 LEFT AND 31 RIGHT. REPAIR ACCOMPLISHED CORROSION REMOVAL, FABRICATION AND INSTALLATION OF A REPAIR FILLER AND AN EXTERNAL REPAIR DOUBLER IN ACCORDANCE WITH FAA DER APPROVED DRAWING F03-0-R047 AND ENGINEERING ORDER 53-DC8-930.

Part: PANEL — DAMAGED (WS 408)

DURING ROUTINE C CHECK INSPECTION, RIGHT WING LOWER LEADING EDGE ACCESS PANEL WAS DAMAGED AT STATION XW 408. REPAIR ACCOMPLISHED REMOVAL OF DAMAGED AREA, FABRICATION AND INSTALLATION OF A REPAIR FILLER, DOUBLER AND AN L ANGLE IN ACCORDANCE WITH FAA DER APPROVED DRAWING F03-R01 AND ENGINEERING ORDER 57-DC8-924

Part: PLATING — CORRODED (RT AILERON)

DURING ROUTINE C CHECK INSPECTION, A CORROSION BULGE AND POPPED RIVET HEADS WERE DETECTED ON THE RIGHT AILERON LOWER PLATING BETWEEN STATIONS XA 605 AND XA 622. REPAIR ACCOMPLISHED REMOVAL OF DAMAGED PLATING, FABRICATION AND INSTALLATION OF A NEW LOWER PLATING IN ACCORDANCE WITH FAA DER APPROVED DRAWING F03-R02 AND ENGINEERING ORDER 27-DC8-905-925.

Part: CONTROL BOX — DEFECTIVE (ANTISKID SYST)

DURING LANDING ROLL, ALL HYDRAULIC BRAKING ACTION WAS LOST. THE CREW INITIATED THE EMERGENCY BRAKING SYSTEM AND MAXIMUM REVERSE THRUST TO DECELERATE THE AIRCRAFT. MAINTENANCE INSPECTED THE AIRCRAFT ANTI-SKID SYSTEM AND REPLACED THE ANTI-SKID CONTROL BOX. AN OPERATIONAL CHECK WAS ALSO ACCOMPLISHED ON THE AIRBRAKE SYSTEM IN ACCORDANCE WITH THE MAINTENANCE MANUAL AND THE AIRCRAFT WAS RETURNED TO SERVICE.

Part: CONTROL BOX — DEFECTIVE (ANTI-SKID SYST)

DURING LANDING ROLL AT WRI, ALL HYDRAULIC BRAKING ACTION WAS LOST. THE CREW INITIATED THE EMERGENCY AIR BRAKE SYSTEM TO DECELERATE THE AIRCRAFT. NORMAL BRAKING WAS RESTORED AFTER THE CREW DISARMED THE ANTI-SKID SYSTEM. MAINTENANCE INSPECTED THE AIRCRAFT AND FOUND THE ANTI-SKID CONTROL BOX DEFECTIVE, AND WAS REPLACED. A SUCCESSFUL OPERATIONAL TEST WAS PERFORMED IN ACCORDANCE WITH THE DOUGLAS MAINTENANCE MANUAL.

Part: BATTERY PACK — DISCHARGED (CABIN)

AFTER ARRIVING AND ENGINE SHUTDOWN WITH NO EXTERNAL ELECTRICAL POWER, THE COCKPIT AND PASSENGER COMPARTMENT DOOR OVERHEAD EMERGENCY LIGHTING FAILED TO ILLUMINATE. MAINTENANCE INSPECTED THE EMERGENCY LIGHTING SYSTEM AND FOUND TWO BATTERY PACKS DEFECTIVE, WHICH WERE REPLACED. MAINTENANCE ACCOMPLISHED A SUCCESSFUL OPERATIONAL TEST IN ACCORDANCE THE DOUGLAS MAINTENANCE MANUAL.

Part: FLOORBEAM — CRACKED (BS 226-270)

DURING ROUTINE C-CHECK INSPECTION, FLOORBEAM BETWEEN FUSELAGE STATION 226 AND 270 WAS FOUND TO BE CRACKED. REPAIR OF THE FLOORBEAM WAS ACCOMPLISHED BY FABRICATING AND INSTALLING REPAIR DOUBLERS IN ACCORDANCE WITH FAA DER APPROVED SKETCH B68-R29 AND THE DOUGLAS STRUCTURAL REPAIR MANUAL.

Part: GUSSET — CORRODED (BS 128)

DURING ROUTINE C-CHECK INSPECTION, A CORRODED GUSSET AT FUSELAGE STATION 128 AND LONGERON 22 LEFT WAS FOUND. THE GUSSET WAS REMOVED, FABRICATED AND INSTALLED IN ACCORDNACE WITH THE DOUGLAS STRUCTURAL REPAIR MANUAL 53-1-0, AND FAA DER APPROVED SKETCH B68-R16.

Part: FITTING — CRACKED (RT MLG)

DURING ROUTINE C-CHECK INSPECTION, THE RIGHT MAIN LANDING GEAR ATTACH FITTING WAS FOUND TO BE CRACKED. THE ATTACH FITTING WAS REPLACED IN ACCORDANCE WITH THE DOUGLAS REPLACEMENT GUIDE AND SRM 51-1-21.

Part: LONGERON — CRACKED (RT MLG WW)

DURING ROUTINE C-CHECK INSPECTION, LONGERON 24 RIGHT WAS FOUND TO BE CRACKED IN TWO PLACES ADJACENT TO THE BATHTUB FITTING AT FUSELAGE STATION 870. THE CRACKS WERE STOP DRILLED, REPAIR DOUBLERS FABRICATED AND INSTALLED IN ACCORDANCE WITH DOUGLAS STRUCTURAL REPAIR MANUAL 53-2-2 AND 51-1-20D.

Part: FITTING — CRACKED (LT MLG)

DURING ROUTINE C-CHECK INSPECTION, THE LEFT MAIN LANDING GEAR ATTACH FITTING WAS FOUND TO BE CRACKED. THE ATTACH FITTING WAS REPLACED IN ACCORDANCE WITH THE DOUGLAS REPLACEMENT GUIDE AND SRM 51-1-21.

Part: PROX SWITCH — DIRTY (MLG DOORS)

ON TAKEOFF OUT OF BGTL, THE MLG 'NOT LATCHED' LIGHT CAME ON AFTER GEAR RETRACTION. THE GEAR WAS CYCLED, WITH NO CHANGE IN THE INDICATION. THE UPLATCH CHECK WAS NORMAL. AT KWRI, MAINTENANCE INSPECTED THE AIRCRAFT AND DETERMINED THE PROBLEM TO BE CAUSED BY DIRTY GEAR DOOR PROXIMITY SWITCHES. THE SWITCHES WERE CLEANED, THE DOOR UPLATCH ASSEMBLY PRECAUTIONARILY LUBRICATED, AND OPS CHECKS ACCOMPLISHED IAW THE DC-8 MM. DOOR INDICATION RETURNED TO NORMAL OPERATION, AND THE AIRCRAFT WAS RETURNED TO SERVICE. (M)

Part: AIR DISTR — ODOR (CABIN)

EN ROUTE BETWEEN LPLA AND KWRT, THE AIR CONDITIONING SYSTEM INTERMITTENTLY PRODUCED THE STRONG SMELL OF OIL IN THE COCKPIT. THE FLIGHT CREW SUSPECTED A TURBOCOMPRESSOR OIL SEAL FAILURE. INSPECTION ON THE GROUND IN KWRT SHOWED THE TC'S TO BE NORMAL, WITH NO LEAKAGE OF LOSS OF OIL. NO OTHER SOURCE COULD BE IDENTIFIED FOR THE INTERMITTENT SMELL. (M)

Part: FAN — FAILED (LEFT)

DURING FLIGHT BETWEEN PJON AND PHNL, THE LEFT RECIRCULATION FAN PRODUCED FUMES WHICH WERE THEN CIRCULATED INTO THE AIRCRAFT. THE RECIRCULATION FAN WAS DEFERRED AND SCHEDULED FOR REPLACEMENT. (M)

Part: FIRE DETECTOR — MALFUNCTIONED (NR 3 ENGINE)

KWRI - ON DEPARTURE OUT OF KWRI, A NR 3 ENGINE FIRE WARNING WAS EXPERIENCED. THE ENGINE WAS PRECAUTIONARILY SHUT DOWN, AND THE AIRCRAFT RETURNED TO KWRI FOR MAINTENANCE. WINDMILLING OIL PRESSURE WAS 30 PSI. INSPECTION AT KWRI REVEALED AN INTERMITTENTLY BAD LOWER FIRE DETECTOR ELEMENT. THE FIRE DETECTOR ELEMENT WAS REPLACED, AND THE ENGINE RUN EXTENSIVELY ON THE GROUND TO VERIFY THE REPAIR. THERE WAS NO RECURRING FALSE FIRE WARNING. THE AIRCRAFT RETURNED TO SERVICE. (X)

Part: DUCT CLAMP — FAILED (NR 3 ENGINE)

LPLA/KWRI - IN CRUISE BETWEEN LPLA AND KWRI, A NR 3 ENGINE FIRE WARNING WAS EXPERIENCED WITH NORMAL ENGINE PARAMETERS OBSERVED. THE ENGINE WAS PRECAUTIONARILY SHUT DOWN, AND THE FIRE BOTTLES DISCHARGED. THE FIRE WARNING EXTINGUISHED AND THE ENGINE MAINTAINED 39 PSI WINDMILLING OIL PRESSURE. INSPECTION ON THE GROUND AT KWRI REVEALED A FAILED CLAMP ON THE 9TH STAGE PNEUMATIC BLEED DUCT. THE CLAMP WAS REPLACED AND THE SYSTEM LEAK-CHECKED. THE FIRE BOTTLES WERE REPLACED, AND THE AIRCRAFT WAS RETURNED TO SERVICE. (X)