N3199Q

Part: PRESSURE SWITCH — SHORTED (A/C SYSTEM) · airframe 21,568 hrs · 29,509 cycles

DURING CLIMB, BOTH ENVIR FAIL LIGHTS CAME ON, CREW RETURNED TO STATION WITH NO FURTHER INCIDENT. LEFT SYSTEM WAS INITIALLY REPAIRED BY REPLACING PRECOOLER THRU VALVE & BYPASS VALVE. AFTER EXTENSIVE TROUBLESHOOTING, THE RIGHT SYSTEM WAS REPAIRED BY REPLACING SHORTED PRESSURE SWITCH. THIS SWITCH WAS INTERMITTENTLY & PARTIALLY INTERNALLY SHORTED BETWEEN 4 OF THE PINS TO EACH OTHER AND TO THE CASE. THIS INTERMITTENT FAULT IS SUSPECTED TO BE ROOT CAUSE OF THIS INCIDENT.

Part: PIN — NOT SEATED (ENVIRON SYS) · airframe 21,560 hrs · 29,498 cycles

CREW REPORTED THE LEFT ENVIRO FAIL CAME ON AT 1000 FT AGL, SYSTEM WAS RECYCLED PER THE CHECKLIST, AND CAME ON AGAIN AT 5000 FT AGL. CREW RETURNED TO STATION. THE RIGHT ENVIRONMENTAL SYSTEM WAS PREVIOUSLY DEFERRED. LEFT SIDE OF OVERPRESSURE SWITCH CONNECTOR HAD A PIN IN THE CONNECTOR THAT WAS FOUND UNSEATED. RESEATED PIN. RIGHT SIDE DEFERRAL WAS CLEARED BY CLEANING & RESEATING CONNECTOR P563 TO THE OVERPRESSURE SWITCH. GROUND RUN OPERATIONAL & FUNCTION CHECK WERE GOOD. AN OPERATIONAL CHECK FLIGHT WAS COMPLETED, BOTH SYSTEMS OPS CHECK NORMALLY.

Part: SWITCH — OUT OF ADJUST (PAX DOOR) · airframe 20,914 hrs · 28,714 cycles

DURING CLIMBOUT THROUGH 10,000 FT THE CABIN DOOR WARNING LIGHT CAME ON. CREW FOLLOWED EMERGENCY CHECKLIST PROCEDURES & RETURNED TO THE STATION. THE MICROSWITCH ON LATCH CAM INSIDE THE DOOR WAS FOUND SLIGHTLY OUT OF ADJUSTMENT DUE TO WEAR & WAS ADJUSTED. THE DOOR WARNING SYSTEM OPS CK GOOD AFTER ADJUSTMENT. THE WEAR ONLY MANIFESTED ITSELF AS THE AIRCRAFT WAS PRESSURIZED.

Part: WIRE — CHAFED (MLG) · airframe 20,043 hrs · 27,349 cycles

CREW SELECTED GEAR DOWN IN PREPARATION FOR LANDING. THE GEAR INDICATOR CB POPPED, CREW RESET THE CB, & REPLACED BURNED OUT NLG INDICATOR BULBS. THE GEAR WAS CYCLED UP AND DOWN, WITH NORMAL OPERATION. AN OPERATIONAL CHECK FLIGHT WAS PERFORMED AFTER MAINTENANCE INITIALLY INSPECTED THE AIRCRAFT WITH NO DEFECTS NOTED. THE PROBLEM WAS FINALLY TRACED TO A CHAFED GEAR UP MICROSWITCH WIRE LOCATED BEHIND THE GRAVEL GUARD ABOVE THE MAIN WHEEL ASSEMBLIES.

Part: COMBUSTION CASE — CORRODED (ENGINE) · airframe 19,863 hrs · 27,427 cycles

CREW ABORTED TAKEOFF DUE TO LOW POWER INDICATION AT MAX CONTINUOUS ITT. DURING THE TROUBLESHOOTING FOR THIS PROBLEM A SMALL PINHOLE WAS FOUND CORRODED IN THE EXTERNAL COMBUSTION CASE JUST FORWARD OF THE AFT DRAIN. THE ENGINE WAS REMOVED FOR REPAIR. THE AIR LOSS AT THE PINHOLE IS NOT ENOUGH TO HAVE CAUSED THE INDICATED POWER LOSS EXPERIENCED BY THE CREW. AS A NOTE, THE SUSPECTED CAUSE OF LOW POWER IS THOUGHT TO BE EITHER A LOW T5 RESISTANCE CHECK, AS 300 OHMS WAS NOTED INSTEAD OF A MINIMUM OF 5,00 OHMS, OR COMPRESSOR SECTION DETERIORATION IN THE INTERMEDIATE COMPRESSOR ROTORS OR STATORS.

Part: CIRCUIT BOARD — FAILED (LANDING GEAR SYS) · airframe 19,764 hrs · 27,301 cycles

CREW DIDN'T GET A GEAR NOT DOWN WARNING WHEN THROTTLES WERE RETARDED, WHEN THE LANDING GEAR WAS SELECTED DOWN, THERE WAS NO RED INTRANSIT LIGHT AND THE GEAR DOWN 3 GREEN INDICATORS DIDN'T COME ON. CREW PERFORMED A FLYBY OF THE TOWER, WHICH VERIFIED ALL 3 GEAR WERE EXTENDED. CREW PERFORMED MANUAL EXTENSION PROCEDURES TO VERIFY GEAR WAS LOCKED DOWN. CREW LANDED WITH NO FURTHER PROBLEMS. MAINTENANCE FOUND LANDING GEAR TIME DELAY PRINTED CIRCUIT BOARD HAD FAILED. PART WAS REPLACED AND LANDING GEAR AND SYSTEMS OPS CHECKED GOOD.

Part: STATIC INVERTER — INOPERATIVE · airframe 19,406 hrs · 26,841 cycles

DURING INITIAL CLIMB AT APPROX 200FT AGL THE LT AC BUSS FAILED, CREW TRIED RESET, AND THIS DIDN'T WORK, TRANSFER WAS SELECTED AND WORKED, CREW RETURNED TO STATION. FOUND STATIC INVERTER FAILED, REPLACED UNIT AND DURING SUBSEQUENT RUNS, FOUND INVERTER COOLING FAN HAD ALSO FAILED, REPLACED COOLING FAN, SYSTEM OPS CK GOOD DURING INTIAL 45 MINUTE GROUND OPS CK. ALSO FOUND WIRE DAMAGED BY SCREW CONTACTING WIRE GOING TO THE NR 1 INVERTER POWER SELECT, CAUSING A SECONDARY INTERMITTENT FAULT. WIRE WAS REPAIRED AND SCREW REPLACED, SYSTEM OPS CK GOOD.

Part: ACTUATOR — STIFF (ELEVATOR TRIM) · airframe 15,584 hrs · 21,670 cycles

DURING FLIGHT, CREW DISCOVERED THE ELEVATOR TRIM WAS STIFF AND HAD DIFFICULTY MOVING THE ELEVATOR TRIM WHEEL. THE LT ELEVATOR CLEVES WAS ADJUSTED AND THE ACFT WAS RETURNED TO SERVICE.

Part: BOLT — LOOSE (RUDDER) · airframe 15,581 hrs · 21,661 cycles

DURING A NR 6 DETAIL, IT WAS FOUND THAT THE FOUR BOLTS SECURING THE RUDDER TORQUE TUBE TO THE RUDDER AT THE LOWER ATTACH POINT FLANGE WERE LOOSE. CAUSING PLAY IN THE RUDDER CONTROL SYS AFTER REPLACING THE 4 BOLTS AND PERFORMING RUNNING TORQUE TESTS ON THE FASTENERS. SERVICED ACFT WITHOUT FURTHER INCIDENTS.

Part: RIB — CRACKED (VERTICAL STAB.) · airframe 15,241 hrs · 21,232 cycles

2 CRACKS FOUND IN THE RIB. IN JOGGLED SECTION OVER STRNG AT LAST RIVET. CRACKS LOCATED AT STRNG P/N 101-640000-37 AND 10-640000-46.

Part: RIB — CRACKED (VERTICAL STAB) · airframe 15,241 hrs · 21,232 cycles

FIVE CRACKS FOUND IN THE RIB IN JOGGLED PARTS OF RIB AT STRING INTERSECTIONS. STRING P/N 101-640000-46, 101-640000-39, 101-640000-45, 101-640000-38. CRACKS RUN HORIZONTAL TO RIB FROM LAST RIVET HOLE TO EDGE OF RIB.

Part: CONTROL ROD — OUT OF POSITION (RIGHT) · airframe 14,726 hrs · 20,541 cycles

ON FLIGHT 5445 FROM PANAMA CITY FLORIDA TO TAMPA FLORIDA, DURING TAKEOFF ROLL THE RIGHT POWER LEVER WAS STUCK. THE AIRCRAFT DID NOT MAKE TAKEOFF TORQUE. THE TAKEOFF WAS ABORTED AND THE AIRCRAFT RETURNED TO GATE WITH NO FURTHER INCIDENT. MAINTENANCE REPOSITIONED THE CONTROL ROD. NO PARTS WERE USED. THEREFORE NO TEARDOWN REPORT WILL BE REQUIRED.

Part: PRESSURE SWITCH — OUT OF ADJUST (CABIN PRESSURE) · airframe 13,616 hrs · 19,140 cycles

DURING THE CLIMB PHASE ON FLIGHT 106 FROM COLORADO SPRINGS TO ALBUQUERQUE, THE HIGH ALTITUDE ANNUNCIATOR ILLUMINATED. THE OXYGEN MASK WAS DEPLOYED. THE APPROPRIATE MEMORY ITEMS AND THE CABIN ALTITUDE HIGH EMERGENCY CHECKLIST WAS COMPLETED. DURING THE DESCENT, THE CABIN ALTITUDE HIGH ANNUNCIATOR EXTINGUISHED. FURTHER DESCENTS WERE APPROVED AS THE TERRAIN PERMITTED. THE MASKS REMAINED DOWNED AS A PRECAUTION UNTIL AIRCRAFT DESCENDED THROUGH 10,000FEET. THE AIRCRAFT LANDED WITHOUT INCIDENT. THE CORRECTIVE ACTION WAS THAT THEY REMOVED AND RE-ADJUSTED THE CABIN ALT PRESSURE SWITCH. NO PARTS WERE USED.

Part: SWITCH — LOOSE (PAX DOOR) · airframe 13,330 hrs · 18,770 cycles

AFTER DEPARTURE ON FLIGHT 5637, THE CABIN DOOR ANNUNCIATOR ILLUMINATED. THE AIRCRAFT WAS THEN DIVERTED TO PANAMA CITY, FLORIDA WHERE MAINTENANCE INSPECTED THE DOOR AND DEFERRED THE ANNUNCIATOR SYSTEM. THE CORRECTIVE ACTION WAS THAT AFTER THE INSPECTION OF THE DOOR, THE LATCH SWITCH ARM WAS FOUND TO BE LOOSE. MAINTENANCE REPLACED THE AFT LATCH SWITCH AND THE AIRCRAFT WAS THEN RETURNED TO SERVICE. NO TEARDOWN REPORT REQUIRED.

Part: ATTACH BRACKET — EXCESS WEAR (LT FLAP)

FLEET CAMPAIGN, 'MAINTENANCE INSPECTED THE LT AND RT OTBD FLAP ATTACHMENT BRACKETS AND THE AFT ROLLER BEARING IAW RAYTHEON ACFT CO (RAC) SAFETY COMMUNIQUE NR 137 DATED MAY, 1997. FOUND ATTACHMENT BRACKETS WITH EXCESSIVE WEAR AND AFT ROLLER BEARINGS BINDING. AFFECTED COMPONENTS P/NS ARE BRACKET, LT INBD AND RT INBD, INBD HINGE, PN 35-165050-31. BRACKET, LT LTBD AND RT INBD, INBD HINGE, PN 35-165050-30. BRACKET, LT INBD AND RT OTBD, OTBD HINGE, PN 35-165050-35. BRACKET, LT OTBD AND RT INBD, OTBD HINGE, PN 35-165050-34. AFT BEARING ASSY, PN 114-521039-1. REF: CONTROL NR MASA97045. PART CYCLES, 2,330. ACFT TC, 2,330.