N31CX

Part: VALVE — DAMAGED (A/C BAY) · airframe 76,597 hrs · 29,783 cycles

ON CLIMBOUT FROM PHIK THE LEFT PACK DUCT TEMPERATURE WENT TO 80 DEGREES. CREW TURNED OFF PACK AND THE TEMPERATURE WENT UP. CREW RETURNED TO PHIK AND LANDED WITH OUT INCIDENT. MAINTENANCE REMOVED AND REPLACED LEFT AIR MIX VALVE IN ACCORDANCE WITH ALL APPLICABLE MANUALS. SYSTEM OPERATIONAL CHECK GOOD. AIRCRAFT RETURNED TO SERVICE.

Part: GYRO — FAILED (COCKPIT) · airframe 76,461 hrs · 29,757 cycles

AFTER TAKEOFF FROM WSAP NR 1 COMPASS PRECESSING 8-10 DEGREES IN APPROX. 1 1/2 MINUTES. CREW RETURNED TO WSAP AND LANDED WITHOUT INCIDENT. AN INSPECTION IS ON GOING. WILL PROVIDE MORE INFORMATION AS IS BECOMES AVAILABLE. MAINTENANCE REMOVED AND REPLACED NR 1 DIRECTIONAL AND VERTICAL GYRO PER ALL APPLICABLE MANUALS. OPERATIONAL AND LEAK CHECK GOOD. AIRCRAFT WAS RETURNED TO SERVICE.

Part: INDICATOR — MALFUNCTIONED (COCKPIT) · airframe 75,848 hrs · 29,602 cycles

AFTER DEPARTURE FROM BWI CREW NOTICED FIRST OFFICERS HORIZONTAL SITUATION INDICATOR WOULD NOT ROTATE. CREW DIVERTED TO WRI FOR AN UNEVENTFUL LANDING. MAINTENANCE REPLACED INSTRUMENT AMPLIFIER AND FIRST OFFICERS HORIZONTAL SITUATION INDICATOR IAW WITH THE AIRCRAFT MAINTENANCE MANUAL, PERFORMED A SUCCESSFUL OPERATIONAL CHECK AND RETURNED THE AIRCRAFT TO SERVICE.

Part: FAN — DEFECTIVE (FWD BELLY) · airframe 74,718 hrs · 29,259 cycles

ENROUTE FROM KWI TO AVB, THE FLIGHT CREW SENSED AN ODOR IN THE COCKPIT WHEN BOTH RECIRCULATION FANS WERE OPERATING. THE FLIGHT CREW SECURED THE FANS AND THE ODOR SUBSIDED. THE FLIGHT CONTINUED FOR AN UNEVENTFUL LANDING. MAINTENANCE INSPECTED THE AIRCRAFT AND FOUND THE FANS TO BE DEFECTIVE. THE FANS WERE PLACED ON DEFERRAL AND THE AIRCRAFT WAS RETURNED TO SERVICE.

Part: LINE — LOOSE (WHEEL WELL) · airframe 73,645 hrs · 28,943 cycles

ENROUTE FROM AKJ TO AVB, THE FLIGHT CREW NOTICED A DECLINE IN THE MAIN HYDRAULIC QUANTITY SYSTEM. THE FLIGHT CREW FOLLOWED COMPANY PROCEDURES AND CONTINUED TO AVB FOR AN UNEVENTFUL LANDING. MAINTENANCE INSPECT THE AIRCRAFT LOCATING A LOOSE LINE ON THE RIGHT MAIN HYDRAULIC MANIFOLD. MAINTENANCE SECURED THE LINE AND PERFORM A SUCCESSFUL OPERATIONAL CHECK IN ACCORDANCE WITH THE MAINTENANCE MANUAL. THE AIRCRAFT WAS RETURNED TO SERVICE.

Part: FAN — DEFECTIVE (FWD BELLY) · airframe 73,590 hrs · 28,927 cycles

ENROUTE FROM RMS TO AVB, THE FLIGHT CREW SENSED AN ODOR IN THE COCKPIT WHEN THE LEFT RECIRCULATION FAN WAS OPERATING. THE FLIGHT CREW SECURED THE FAN AND THE ODOR SUBSIDED. THE FLIGHT CONTINUED TO AVB FOR AN UNEVENTFUL LANDING. MAINTENACE INSPECT THE FAN WHICH WAS FOUND DEFECTIVE. MAINTENANCE PLACED THE FAN ON DEFERRAL. THE AIRCRAFT WAS RETURNED TO SERVICE.

Part: CONNECTOR — LOOSE (NLG) · airframe 73,562 hrs · 28,918 cycles

EN ROUTE FROM RMS TO AVB, AFTER THE LANDING GEAR WAS RETRACTED THE GEAR UNSAFE LIGHT REMAINED ILLUMINATED. THE FLIGHT CREW CYCLED THE LANDING GEAR BUT THE WARNING INDICATION REMAINED THE SAME. THE FLIGHT RETURNED TO RMS FOR AN UNEVENTFUL LANDING. MAINTENANCE INSPECTED THE LANDING GEAR WARNING SYSTEM LOCATING A LOOSE CANNON PLUG ON THE NOSE LANDING GEAR POSITION SWITCH. MAINTENANCE SECURED THE CANNON PLUG, PERFORM A SUCCESSFUL OPERATIONAL CHECK IN ACCORDANCE WITH THE MAINTENANCE MANUAL. THE AIRCRAFT WAS RETURNED TO SERVICE.

Part: LINE — DEFECTIVE (LT GEAR) · airframe 73,365 hrs · 28,857 cycles

DURING CRUISE FROM AVB TO RMS, THE FLIGHT CREW NOTICED THAT THE MAIN HYDRAULIC QUANTITY SYSTEM WAS DECLINEING. THE FLIGHT CREW FOLLOWED COMPANY PROCEDURES AND CONTINUED TO RMS FOR AN UNEVENTFUL LANDING. MAINTENANCE INSPECTED THE AIRCRAFT LOCATE A DEFECTIVE SUPPLY LINE ON THE LEFT MAIN GEAR BOGIE TRIM CYCLINER. MAINTENANCE REPLACED THE SUPPLY AND PERFORM AND OPERATIONAL CHECK IN ACCORDANCE WITH THE MAINTENANCE MANUAL. THE AIRCRAFT WAS RETURNED TO SERVICE.

Part: FLOORBEAM — CRACKED (FUSELAGE) · airframe 73,325 hrs · 28,844 cycles

DURING ROUTINE C-CHECK INSPECTION, A CRACK WAS DETECTED ON THE FLOOR BEAM AT FUSELAGE STATION 879, LBL-61. REPAIR ACCOMPLISHED REMOVAL OF DAMAGED AREA, FABRICATION AND INSTALLATION OF A BEAM FILLER AND REPAIR SPLICE ANGLES IN ACCORDANCE WITH DOUGLAS STRUCTURAL REPAIR MANUAL AND ENGINEERING ORDER 51-DC8-1809.

Part: LONGERON — CORRODED (F.S. 21) · airframe 73,325 hrs · 28,844 cycles

DURING ROUTINE C-CHECK INSPECTION, CORROSION WAS DETECTED AT FUSELAGE STATION 902 BETWEEN LONGERONS LONGERON 21R AND LONGERONS 20R. REPAIR ACCOMPLISHED REOVAL OF DAMAGED AREA, FABRICATION AND INSTALLATION REPAIR FILLERS AN EXTERNAL DOUBLERS IN ACCORDANCE WITH DOUGLAS STRUCTURAL REPAIR MANUAL AND ENGINEERING ORDER 53-DC8-1808.

Part: FAN — DEFECTIVE (A/C BAY) · airframe 72,989 hrs · 28,756 cycles

EN ROUTE FROM HIK TO JON, THE FLIGHT CREW EXPERIENCED SMOKE IN THE AIRCRAFT. THE FLIGHT CREW SECURED THE RIGHT RECIRULATION FAN, THE SMOKE SUBSIDED. THE FLIGHT CONTINUED TO JON FOR AN UNEVENTFUL LANDING. MAINTENANCE INSPECTED THE AIRCRAFT WHICH REVEALED THE RIGHT RECIRULATION FAN DEFECTIVE. MAINTENANCE PLACED THE FAN ON DEFERRAL AND THE AIRCRAFT WAS RETURNED TO SERVICE.

Part: DUCT — LOOSE (ACM BAY)

EN ROUTE FROM KWI TO AVB, THE FLIGHT CREW HEARD CREW HEARD A BANG FROM THE TURBO COMPRESSOR BAY ARE FOLLOWED BY LOSS OF CABIN PRESSURIZATION. THE FLIGHT CREW FOLLOWED COMPANY EMERGENCY PROCEDURES AND DESCENTED TO A SAFE ALTITUDE. THE FLIGHT CONTINUED TO AVB FOR AN UNEVENTFUL LANDING. MAINTENANCE INSPECTED THE AIRCRAFT LOCATING AN UNSECURED DUCT AT THE NUMBER FOUR TURBO COMPRESSOR CHECK VALVE. MAINTENANCE SECURED THE DUCT AND PERFORMED A SUCCESSFUL OPERATIONAL TEST. THE AIRCRAFT WAS RETURNED TO SERVICE. (M)

Part: BULB — FAILED (CABIN)

THE FLIGHT CREW PERFORMED A POST FLIGHT CHECK LIST AT OKO, WHICH REVEALED TWO PASSENGERS EMERGENCY EXIT AISLE PATHWAY LIGHTS INOPERATIVE. MAINTENANCE REPLACED TWO LIGHT BULBS AND PERFORMED A SUCCESSFUL OPERATIONAL CHECK.

Part: BULKHEAD CAP — CRACKED (BS 1606)

DURING ROUTINE C CHECK INSPECTION, A CRACK WAS DETECTED ON THE AFT PRESSURE BULKHEAD UPPER CAP AT FUSELAGE STATION 1606. REPAIR WAS ACCOMPLISHED BY STOP DRILLING OF CRACK, FABRICATION AND INSTALLATION OF A REPAIR ANGLE DOUBLER AND TRIPLER IN ACCORDANCE WITH FAA DER APPROVED DRAWING E22-R04 AND ENGINEERING ORDER 53-DC8-836.

Part: FITTING — CRACKED (BS 781.5)

DURING ROUTINE C CHECK INSPECTION, A CRACK WAS DETECTED ON FUSELAGE FRAME FITTING AT FUSELAGE STATION 781.5 RIGHT INBOARD AREA. REPAIR ACCOMPLISHED BY REMOVAL OF DAMAGED AREA, FABRICATION AND INSTALLATION OF A MILLED ANGLE PLATE IN ACCORDANCE WITH DOUGLAS FAX MESSAGE ACTION NR 365160/365206, FILE NR98-04-03-012, ROD SKETCH NR 98-03-18-016 AND ENGINEERING ORDER 53-DC8-837.

Part: PLATING — CRACKED (WS 120)

DURING ROUTINE C CHECK INSPECTION, A CRACK WAS DETECTED ON LEFT WING UPPER EXTERNAL PLATING ADJACENT TO THE REAR SPAR AT STATION XW120. REPAIR ACCOMPLISHED BY REMOVAL OF DAMAGE AREA, FABRICATION AND INSTALLATION A REPAIR FILLER AND AN EXTERNAL REPAIR DOUBLER IN ACCORDANCE WITH FAA DER APPROVED DRAWING E22-R01 AND ENGINEERING ORDER 57-DC8-827.

Part: PLATING — CORRODED (BS 1268)

DURING ROUTINE C CHECK INSPECTION, CORROSION WAS FOUND ON THE FUSELAGE EXTERNAL PLATING AT STATION 1268 BETWEEN LONGERONS 35 AND 36 LEFT. REPAIR ACCOMPLISHED BY REMOVAL OF DAMAGED AREA, FABRICATION AND INSTALLATION OF AN INTERNAL REPAIR FILLER AND AN EXTERNAL REPAIR DOUBLER IN ACCORDANCE WITH FAA DER APPROVED DRAWING E22-R02 AND ENGINEERING ODER 53-DC8-833.

Part: PLATING — CRACKED (WS 736-761)

DURING ROUTINE C CHECK INSPECTION, TWO CRACKS WERE DETECTED ON RIGHT WING LOWER LEADING EDGE EXTERNAL PLATING BETWEEN STATION 736.5 AND 761.695. REPAIR WAS ACCOMPLISHED BY REMOVAL OF DAMAGED AREAS, FABRICATION AND INSTALLATION REPAIR FILLERS AND EXTERNAL REPAIR DOUBLER IN ACCORDANCE WHIT FAA DER APPROVED DRAWING E33-R03 AND ENGINEERING ORDER 57-DC8-834.

Part: FITTING — CORRODED (BS 960)

DURING ROUTINE C CHECK INSPECTION, CORROSION WAS DETECTED ON FLOOR CUSP VERTICAL SUPPORT FITTING AT FUSELAGE STATION 960 LONGERON 21 LEFT. REPAIR WAS ACCOMPLISHED BY CORROSION REMOVAL, FABRICATION AND INSTALLATION OF AN REPAIR FITTING AND A REPAIR DOUBLER IN ACCORDANCE WITH DOUGLAS STRUCTURAL REPAIR MANUAL 53-20-0, 51-1-8 AND ENGINEERING ORDER 53-DC8-98.

Part: PT2 SYSTEM — CONTAMINATED (NR 1/2)

ON TAKEOFF FROM COF, NR 3 AND NR 4 ENGINE PRESSURE RATIO INDICATION SYSTEMS READ HIGH COMPARED TO N1 AND THE NR 1 AND NR 2 ENGINES. THE FLIGHT ELECTED TO RETURN TO THE FIELD. MAINTENANCE REMOVED INSECT DEBRIS FROM BOTH ENGINE PT2 SYSTEMS, ACCOMPLISHED A HIGH POWER ENGINE RUN SUCCESSFULLY AND RELEASED THE AIRCRAFT BACK TO SERVICE. (M)

Part: PANEL — CRACKED (HORIZ STAB)

DURING ROUTINE C-CHECK INSPECTION OF THE HORIZONTAL CENTER SECTION, THE LOWER FORWARD PANEL WAS FOUND TO BE CRACKED. THE INSPECTION WAS ACCOMPLISHED IAW DOUG SERVICE BULLETING 55-15, USING THE NDT METHODS. THE PANEL WAS REPLACED. (M)

Part: PANEL — CRACKED (HORIZ STAB)

DURING ROUTINE C-CHECK INSPECTION OF THE HORIZONTAL STABILIZER CENTER SECTION, THE FORWARD UPPER PANEL WAS FOUND TO BE CRACKED. THE INSPECTION WAS WITHIN THE SCOPE OF DOUGLAS SERVICE BULLETIN 55-15, USING THE NDT METHODS CALLED OUT. THE PANEL WAS REPLACED. (M)

Part: PANEL — CRACKED (BS 1583)

DURING ROUTINE C-CHECK INSPECTION, A CRACK WAS IDENTIFIED IN THE FUSELAGE EXTERNAL PLATING AT FUSELAGE STATION 1583 AND LONGERON 22 LEFT. THE CRACK WAS REMOVED BY CUTOUT, THE REPAIR WAS ACCOMPLISHED BY FABRICATING AND INSTALLING A FILLER AND EXTERNAL DOUBLER IAW THE DOUGLAS STRUCTURAL MANUAL 53-2-1. (M)

Part: PANEL — CRACKED (BS 1541)

DURING ROUTINE C-CHECK INSPECTION OF THE UPPER AFT FUSELAGE EXTERNAL PLATING, A CRACK WAS IDENTIFIED AT FUSELAGE STATION 1541, LONGERON 17 RIGHT. REPAIR WAS ACCOMPLISHED BY CRACK CUT OUT, FABRICATION AND INSTALLATION OF A REPAIR FILLER AND EXTERNAL DOUBLER IAW THE DOUGLAS STRUCTURAL REPAIR MANUAL 53-2-1. (M)

Part: PANEL — CORRODED (BS 296)

DURING ROUTINE C-CHECK AND CPCP INSPECTION, CORROSION OF THE EXTERIOR PLATING WAS IDENTIFIED AT FUSELAGE STATION 296 BETWEEN LONGERONS 34 AND 35 RIGHT. THE CORRODED AREA WAS CUT OUT AND REPAIR WAS ACCOMPLISHED BY FABRICATION AND INSTALLATION OF A FILLER AND EXTERNAL DOUBLER IAW DOUGLAS STRUCTURAL REPAIR MANUAL 53-2-1. (M)

Part: ANGLE — CRACKED (VERT STAB)

DURING ROUTINE C-CHECK INSPECTION, THE RIGHT VERTICAL STABILIZER ATTACH ANGLE WAS FOUND CRACKED AND CORRODED AT THE FRONT SPAR. REPAIR OF THE ANGLE WAS ACCOMPLISHED IAW FAA DER APPROVED DRAWING A62-R112. (M)

Part: UPPER MID PANEL — CRACKED (HORIZ STAB)

DURNG ROUTINE C-CHECK INSPECTION OF THE HORIZONTAL STABILIZER CENTER SECTION, THE UPPER MID PANEL WAS FOUND CRACKED. THE INSPECTION WAS ACCOMPLISHED IAW DOUGLAS SERVICE BULLETIN 55-15, USING THE NDT METHODS. THE PANEL WAS REPLACED. (M)

Part: PANEL — CORRODED (BS 1590)

DURING ROUTINE C-CHECK INSPECTION, CORROSION OF THE EXTERIOR PLATING AT FUSELAGE STATION 1590, LONGERON 35 LEFT TO 35 RIGHT WAS IDENTIFIED. THE PANEL WAS REMOVED AND REPLACED FROM STATION 1530 TO 1730, LONGERONS 31 LEFT TO 31 RIGHT. (M)

Part: PANEL — CRACKED (BS 1529)

DURING RUOTINC C-CHECK INSPECTION, AN EXTERNAL FUSELAGE SKIN CRACK WAS IDENTIFIED AT FUSELAGE STATION 1529, LONGERON 17 RIGHT. REPAIR WAS ACCOMPLISHED BY REMOVAL OF THE CRACK, CUT OUT, FABRICATION AND INSTALLATION OF A FILLER AND EXTERNAL DOUBLER IAW THE DOUGLAS STRUCTUAL REPAIR MANUAL 53-2-1. (M)

Part: PLATING — CRACKED (RT WING LE)

DURING ROUTINE C-CHECK INSPECTION, A CRACK WAS FOUND IN THE RIGHT WING LEADING EDGE EXTERNAL PLATING AT STATION XW 761.695. THE CRACK WAS REMOVED BY CUT OUT. THE REPAIR WAS ACCOMPLISHED BY FABRICATION AND INSTALLATION OF A REPAIR FILLER AND EXTERNAL DOUBELR IAW THE DOUGLAS STRUCTURAL REPAIR MANUAL 57-2-1. (M)

Part: PANEL — CRACKED (BS 1559)

DURING ROUTINE C-CHECK INSPECTION OF THE UPPER AFT FUSELAGE EXTERIOR PLATING, A CRACK WAS IDENTIFIED AT FUSELAGE STATION 1559, LONGERON 17 RIGHT. THE CRACK WAS REMOVED BY CUT OUT. THE REPAIR FILLER AND EXTERNAL DOUBLER WERE FABRICATED AND INSTALLED IAW THE DOUGLAS STRUCTURAL REPAIR MANUAL 53-2-1. (M)

Part: DIFFUSER — CRACKED (NR 3 ENG)

EN ROUTE FROM OEDR TO ETAR, NR 3 ENGINE WAS NOTED TO BE LOOSING OIL QUANTITY. THE ENGINE WAS PRECAUTIONARILY SHUT DOWN, AND THE AIRCRAFT DIVERTED TO LIPA FOR MAINTENANCE. ON THE GROUND IN LIPA, MAINTENANCE DETERMINED THAT OIL WAS BEING LOST IN THE GAS PATH, POOLING IN THE TURBINE EXHAUST CASE. THE ENGINE WAS REMOVED FROM SERVICE AND SENT TO THE SHOP. TEARDOWN INSPECTION REVEALED A CRACK IN THE DIFFUSER CASE, CAUSING BEARING SUMP AREAS TO PRESSURIZE, PUSHING OIL INTO THE GASPATH. THE ENGINE WAS REPAIRED, TESTED, AND RETURNED TO SERVICE. (M)