N441J

Part: SKIN — CORRODED (LT ELEVATOR)

DURING C-CHECK INSPECTION, THE FOLLOWING WAS FOUND; LEFT ELEVATOR XE 195-313 T/E LOWER SKIN WITH CORROSION.

Part: PANEL — CORRODED (HORIZONTAL STAB)

DURING C-CHECK INSPECTION, THE FOLLOWING WAS FOUND; LT HORIZONTAL STABILIZER BETWEEN XE 312.500 AND XE 149.000 T/E UPPER PANELS WITH CORROSION.

Part: SKIN — CORRODED (BS 25 S33L)

DURING C-CHECK INSPECTION, THE FOLLOWING WAS FOUND; FUSELAGE EXTERIOR STATION 25, L-33R SKIN WITH CORROSION.

Part: PIN — UNKNOWN · airframe 78,552 hrs · 28,572 cycles

FIRST OFFICER'S COURSE DEVIATION INDICATOR (CDI) DOES NOT CORRESPOND TO OMNI BEARING SELECTOR (OBS) IN FLIGHT. FIRST OFFICER'S HEADING "BUG" DOES NOT CORRESPOND TO SELECTED HEADING. REMOVED AND REPLACED PIN NR 1 AT PTO-117 IN ACCORDANCE WITH M/M 20-50-1 AND W/D 34-1-4; GROUND TEST NORMAL IN ACCORDANCE WITH M/M 34-23-0. IN REF TO ITEM NR 3 - SYSTEM CHECK, GROUND TEST NORMAL AFTER WIRING REPAIRED AT P10-117.

Part: ACTUATOR — LEAKING (RUDDER PACK ACTU) · airframe 78,319 hrs · 28,457 cycles

LOG PAGE NR 116558. ON POST FLIGHT FOUND LEAKING BY EMPANAGE LOWER SIDE REAR STRIKE PAD REAR ACCESS PANEL. REMOVED AND REPLACED RUDDER PACK ACTUATOR IAW MM 27-21-6. LEAK CHECK AND OPERATIONAL CHECK IAW MM 27-20-0 FOUND NORMAL, NO LEAKS NOTICE.

Part: LINE — LEAKING (HYD SYSTEM) · airframe 78,081 hrs · 28,346 cycles

LOST HYD FLUID FROM MAIN HYD RESERVOIR AFTER LANDING. UPON INSPECTION; FOUND FLEX LINE LEAKING ON RT MAIN GEAR TRUCK O/B HYD MANIFOLD NEXT TO BOGGIE TRIM ACTUATOR. REMOVED & REPLACED LINE WITH E EACH FLEX LINE FROM FAK. REPLACED DAMAGE LINE IN HYD SYSTEM ON A TEMPORARY BASIS UNTIL PERMANENT REPAIR CAN BE ACCOMPLISHED IN ACCORDANCE WITH DC-8 M/M 20-00 AND ARROW GMM 6-6-1; AND TRANSFERRED TO MASTER CARRY-OVER CONTROL 07093. REMOVED AND REPLACED FLEX-LINE WITH CORRECT PART NUMBER LINE, P/N 57739-6-4206 IN ACCORDANCE WITH M/M 20-12-0. PRESURIZED HYD SYS, OPS CHECK NORMAL. NO LEAKS NOTED; CLEARED CARRY-OVER 7093.

Part: LINK ASSY — VIBRATION (NLG)

AFTER TAKEOFF AND GEAR RETRACTION, EXPERIENCED CONTINUOUS VIBRATION AND NOISE FROM NOSE WHEEL WELL AREA. RETURNED AND LANDED TO INVESTIGATE. REMOVED AND REPLACED RT NOSE DOOR LINK ASSEMBLY IAW MM. PERFORMED ADJUSTMENT TEST SYSTEM IAW M/M. TEST GOOD.

Part: WIRE — OPEN (NR 2 GENERATOR) · airframe 77,709 hrs · 28,162 cycles

AFTER TAKEOFF, ZNS ON NR 2 GENERATOR WITH LEFT EMERGENCY BUS POWER FAIL LIGHT ON. PERFORMED ABNORMAL CHECKLIST TO NO AVAIL; PERFORMED FUEL DUMP AS PER CHECKLIST. TRANSFERRED TO DMI 19258 AS PER MEL 24-1 CAT-C (ON T/S FOUND NR 2 GENERATOR CAUSING FAIL ZNS). OPENED PYLON PANELS, TROUBLESHOT NR 2 GEN. WIRES, FOUND OPEN; REPAIRED AS PER M/M 24-00-01, OPS CHECK GOOD; CLOSED PYLON PANELS IAW M/M 71-00 AND SRM 51-3-0. CLEARED DMI NR 19258.

Part: GENERATOR — FAILED (AC SYSTEM) · airframe 77,638 hrs · 28,124 cycles

DURING CLIMB-OUT, NR 2 GEN SYSTEM DEVELOPED A ZNS. AFTER PERFORMING ABNORMAL CHECK-LIST ONLY LT EMERGENCY BUSS WAS RESTORED. REMOVED AND REPLACED CSD AND AC GENERATOR IN ACCORDANCE WITH DC-8 M/M 24-10-1 AND 24-20-1. LEAKS CHECKED; NO LEAKS NOTED; GENERATOR (GND) TEST NORMAL IN ACCORDANCE WITH M/M 24-00 AND M/M 71-00.

Part: CONNECTOR — DIRTY (ELEVATOR) · airframe 77,585 hrs · 28,096 cycles

DURING TAXI, ELEVATOR POSITION INDICATOR (EPI) FAILED DURING FLIGHT CONTROL CHECK. TRANSFERRED TO DMI NR 19171 AS PER MEL 27-9 CAT "C". CLEANED AND SECURED ELEVATOR EPI INDICATOR IN ACCORDANCE WITH M/M 31-10-30. OPERATIONAL CHECK NORMAL IN ACCORDANCE WITH M/M 27-30-0. THIS CLEARS DMI 19171.

Part: AMPLIFIER — MALFUNCTIONED (FIRE DETECTION) · airframe 77,047 hrs · 27,829 cycles

AFTER TAKEOFF NR 4 ENGINE FIRE WARNING ILLUMINATED INTERMITTENTLY, SHUT DOWN ENGINE AND RETURNED TO KMIA AFTER FUEL DUMPING. OVERWEIGHT LANDING IN KMIA, SMOOTH LANDING. REMOVED AND REPLACED AMPLIFIER (POSITION NR 4) IN ACCORDANCE WITH MM 26-10-4 AND REMOVED & REPLACED FIRE LOOP AFT LOOP POSITION IN ACCORDANCE WITH MM 26-10-0 CHECKED SYSTEM OK IN ACCORDANCE WITH MM 26-10-0 AND MM 71-00.

Part: FIRE LOOP — SHORTED (NR 4 ENGINE) · airframe 76,759 hrs · 27,713 cycles

ON CLIMBOUT THROUGH 15,000 FT MASTER FIRE WARNING SOUNDED WITH LIGHT INDICATION ON NR 4 ENGINE. PERFORMED EMERGENCY CHECKLIST (RETARDED POWER LEVER, FIRE SHUTOFF LEVER FORWARD, LIGHT CONTINUED ON, FIRE EXT AGENT, LIGHT WENT OUT). COMPLETED CHECKLIST, ALL OTHER SYSTEMS NORMAL. RETURNED TO SBEG WITHOUT INCIDENT. PERFORMED ENGINE VISUAL INSPECTION FOR EVIDENCE OF FIRE; NO EVIDENCE OF FIRE NOTED; PERFORMED ENGINE RUN-UP AND FOUND NO REMOTE LEAKS. DURING ENGINE INSPECTION FOUND LOWER FIRE LOOP ELEMENT SHORTED OUT. REMOVED AND REPLACED LOWER ELEMENT IN ACCORDANCE WITH M/M 26-10-1. PERFORMED ENGINE RUN-UP AND OPERATIONAL CHECK NORMAL IN ACCORDANCE WITH 71-00 AND 26-10-1.

Part: PIN — DAMAGED (MLG) · airframe 76,599 hrs · 27,643 cycles

DURING UP-LATCH CHECK THE GEAR NOT LATCHED, LIGHT ILLUMINATED AND PERFORMED ABNORMAL CHECKLIST, THEN BOTH GEAR NOT LATCHED AND DOOR NOT LATCHED REMAINED ILLUMINATED. REMOVED RT GEAR ASSY SENT TO AAR LANDING GEAR; REPAIRED STUD ASS PART NR 5759145508 ON RT GEAR ASSY S/N 539658. REMOVED LANDING GEAR, DUE TO ACTUATOR STUD LOOSE ON RT GEAR ASSY. REMOVED RT GEAR ASSY. IN ACCORDANCE WITH M/M 32-11-1. INSTALLED RT MAIN GEAR IN ACCORDANCE WITH M/M 32-11-1. PERFORMED GEAR ADJUSTMENT TEST IN ACCORDANCE WITH M/M 32-11-1. OPERATIONAL CHECK OK.

Part: INDICATOR — FAILED · airframe 76,392 hrs · 27,560 cycles

DURING TAXI, FIRST OFFICER'S VERTICAL SPEED INDICATOR (VSI) DISPLAY SHOWS REPEATER ANNUNCIATOR. FAILURE AND NO NEEDLE. REMOVED AND REPLACED TCAS/VSI AT FIRST OFFICER'S SIDE. CHECK SYSTEM ON GROUND OK IN ACCORDANCE WITH MM 34-12-0 AND 34-11-1.

Part: INDICATOR — INOPERATIVE (WX RADAR SYS) · airframe 76,368 hrs · 27,551 cycles

WEATHER RADAR DOES NOT PAINT WEATHER NOR DOES IT WORK IN MAPPING MODE. TEST FUNCTION IS NORMAL; AIRCRAFT RETURNED. REMOVED AND REPLACED WHEATHER INDICATOR IN ACCORDANCE WITH MM 34-00; OPERATIONAL CHECK DUE; REMOVED AND REPLACED RADAR R/T IN ACCORDANCE WITH MM 34-00. CHECK SYSTEM OK IN ACCORDANCE WITH MM 34-41-0; FOR TEST FLIGHT, REFERENCE LOG PAGE 108142, ITEM 4: ON TEST FLIGHT RADAR OPERATIONAL CHECK NORMAL.

Part: TRANSCEIVER — FAILED (WX RADAR SYS) · airframe 76,367 hrs · 27,550 cycles

CLIMBING WEATHER RADAR DOES NOT PAINT WEATHER; AIRCRAFT RETURNED. REMOVED AND REPLACED WEATHER RT AND ANTENNA IAW MM 34-41-0 AND 34-41-1 GROUND TEST NORMAL.

Part: UNKNOWN — UNKNOWN (LT WING) · airframe 76,193 hrs · 27,470 cycles

AFTER APP TAKEOFF POWER HEARD BANG ON LEFT HAND SIDE WING. INSPECTED LEFT HAND WING IN ACCORDANCE WITH MM 57-00; NO OBVIOUS DEFECTS NOTED. ALSO INSPECTED LEFT HAND MAIN LANDING GEAR AND DOORS IN ACCORDANCE WITH MM 32-10-0, NO OBVIOUS DEFECTS NOTED. PERFORMED ENGINE RUN UP AND TAXI IN ACCORDANCE WITH MM 9-00 AND 71-00. ALL PARAMETERS NORMAL; PERFORMED FLIGHT CONTROL CHECK AND FOUND TO BE NORMAL IN ACCORDANCE WITH MM 27-00. COULD NOT DUPLICATE FAULT AT THIS TIME.

Part: FITTING — CRACKED (NR 3 PYLON) · airframe 76,058 hrs · 27,394 cycles

DURING C-CHECK INSPECTION, THE FOLLOWING WAS FOUND; NR 3 PYLON STATION YN 300 APPROX. FOOT STOOL FITTING LEFT SIDE WITH CRACK. REMOVED AND REPLACED FOOT STOOL FITTING FROM NR 3 PYLON IN ACCORDANCE WITH BOEING MESSAGE INW-SCL-04-000084, DATED 22-MAR-04, DOUGLAS AOL 8-854, S/B 57-84, DRAWING NUMBER TUI5753054-501/-502 SF1, DRAWING NR 5613906, 5753029 AND 5802738.

Part: WEB — CORRODED (FUSELAGE) · airframe 76,058 hrs · 27,394 cycles

DURING C-CHECK INSPECTION, THE FOLLOWING WAS FOUND; FUSELAGE INTERIOR BETWEEN STA 1060.000 AND STA 1080.000 LT CUSP WITH CORROSION. ACCOMPLISHED REPAIR IN ACCORDANCE WITH BOEING ROD SKETCH 04-05-18-001. ISSUED FAA FORM 8110-3 APPROVING THIS REPAIR.

Part: CARGO TRACK — CORRODED (FUSELAGE) · airframe 76,058 hrs · 27,394 cycles

DURING C-CHECK INSPECTION THE FOLLOWING WAS FOUND; AFT LOWER CARGO COMPARTMENT BETWEEN STA 940.000 AND STA 1500.000, RBL 58.5 INCHES TRACK WR SECTION WITH CORROSION. REMOVED CORROSION IN ACCORDANCE WITH DC-8 SRM 51-1-8, FOUND TO BE OUT OF LIMITS IN ACCORDANCE WITH DC-8 SRM 53-2-3; REMOVED FLOOR PANELS FROM MAIN CARGO COMPARTMENT IN ACCORDANCE WITH DC-8 MM 53-21-2, CUT OUT TRACK SECTION AND PREPARED NEW TRACK SECTION AND FABRICATED SPLICES IN ACCORDANCE WITH DC-8 SRM 53-2-3, TREATED AND PRIMED REPAIR AREA AND PARTS IN ACCORDANCE WITH DC-8 SRM 51-1-8; INSTALLED PARTS IN ACCORDANCE WITH SRM 53-2-3; REINSTALLED FLOOR PANELS IN ACCORDANCE WITH MM 53-21-2.

Part: KEELBEAM — CRACKED (FUSELAGE) · airframe 76,058 hrs · 27,394 cycles

DURING A C-CHECK INSPECTION, THE FOLLOWING WAS FOUND; LT MAIN LANDING GEAR W/W STATION 920, KEELBEAM LT TEE EXTRUSION WITH 3 INCH CRACK. REPAIRED KEEL WEB STIFFENER AT STA 920 IN ACCORDANCE WITH BOEING MESSAGE INW-SCL-04-00005H, DATED 02 MARCH 04, DC8 SRM 51-2-1, TR 51-130. ISSUED FAA FORM 8110-3 APPROVING THIS REPAIR. ALSO N/R 1437; REPAIRED FUSELAGE KEEL LOWER TEE CAPS IN ACCORDANCE WITH BOEING MESSAGE INW-SCL-04-00005H, DATED 02-MAR-04, DRWAING NUMBER 5754125 & ROD SKETCH 04-02-19-001. ISSUED FAA FORM 8110-3 APPROVING THIS REPAIR. PERFORMED CLOSE VISUAL INSPECTION FOR CRACK PROPAGATION AT "C" CHECK INTERVALS.

Part: BULKHEAD — CORRODED (FUSELAGE) · airframe 76,058 hrs · 27,394 cycles

NR 970. DURING (C) CHECK INSPECTION, NLG WW RT TUNNEL STATION 8.000 PRESSURE BULKHEAD FORWARD FACE. NOSE LANDING GEAR RT FITTING WITH CORROSION AT L-31.

Part: WARNING LIGHT — FALSE ACTIVATION (MLG DOOR) · airframe 75,922 hrs · 27,344 cycles

LANDING GEAR DOOR NOT LATCH LIGHT ILLUMINATED AFTER TAKEOFF; PERFORMED ABNORMAL CHECKLIST, LIGHT WENT OUT. CLEANED, INSPECTED & LUBRICATED LANDING GEARS AND DOORS IAW DC8 MM 12-81-1. ACCOMPLISHED GEARS SWING IAW DC8 MM 32-30-0. NO DEFECTS NOTED.

Part: BLEED VALVE — STUCK (NR 1 ENGINE) · airframe 75,764 hrs · 27,275 cycles

UNABLE TO OBTAIN MAX POWER INDICATION WITH NR 1 TROTTLE AT IT'S FULL FORWARD STOP POSITION. FOUND NR 1 ENGINE SURGE BLEED VALVE STUCK OPEN; REMOVED AND REPLACED NR 1 ENGINE SURGE BLEED VALVE IAW DC-8 MM 75-30-3; OPERATIONAL CHECK NORMAL IAW MM 71-00.

Part: CYLINDER — BROKEN (MLG) · airframe 75,682 hrs · 27,249 cycles

AFTER TAKE-OFF, WHEN GEAR WAS RETRACTED; NOT LATCHED AND DOORS NOT LATCHED. LIGHT REMAINED ILLUMINATED. PERFORMED LANDING GEAR SYSTEM ABNORMAL CHECK LIST AND RETURNED TO MNMG. FOUND RT GEAR BOGIE TRIM CYLINDER BROKEN AT FORWARD ATTACH POINT; REMOVED AND REPLACED RT BOGIE TRIM CYLINDER IAW MM 32-33-1. LEAK CHECKED; NO LEAKS NOTED. ACCOMPLISHED PER ALTERNATE METHOD IAW MM 32-33-1. ALSO FOUND RT GEAR DOOR LATCH ASSEMBLY WITH ARMS BROKEN; REMOVED AND REPLACED ARMS IAW MM 32-12-1 & MM 20-10-1. DOOR OPERATIONAL CHECK NORMAL IAW MM 32-12-1.

Part: DOOR FRAME — CRACKED (FUSELAGE) · airframe 75,643 hrs · 27,231 cycles

DURING ROUTINE INSPECTION THE FOLLOWING WAS FOUND; AFT SERVICE DOOR JAMB, AFT TOP CORNER WITH CRACK OF 1.125 INCH. REPAIRED THE AFT SERVICE DOOR JAMB AFT TOP CORNER IAW SRM 53-2-0 FIG 16, SHEETS 4, 5, 6, 7 & 8 TEMPORARY REVISION 53-156, DATED 12/20/02. (EA 1021, DATED 08/21/03).

Part: DOOR FRAME — CRACKED (FUSELAGE) · airframe 75,643 hrs · 27,231 cycles

DURING ROUTINE INSPECTION THE FOLLOWING WAS FOUND; AFT ENTRANCE DOOR JAMB AFT BOTTOM CORNER WITH CRACKS OF 0.625 & 0.437 INCH. REPAIRED THE AFT ENTRANCE DOOR JAMB AFT BOTTOM CORNER IAW SRM 53-2-0 FIG 18, SHEETS 1, 5, 6, 7 & 8, TEMPORARY REVISION 53-134 & TEMPORARY REVISION 53-158, DATED 01/23/02 & 12/20/02 RESPECTIVELY EA 1020, DATED 08/21/03.

Part: BLEED VALVE — INOPERATIVE (NR 2 ENGINE) · airframe 75,606 hrs · 27,213 cycles

COMPRESSOR STALL NR 2 ENGINE COMMENCING THE TAKE OFF ROLL. REJECTED TAKE OFF (RTO). REMOVED AND REPLACED NR 2 PRESSURE RATIO SURGE BLEED VALVE IAW MM 75-30-3. OPERATIONAL CHECK ON RUN UP IAW MM 71-0 FOUND NORMAL.

Part: TRANSMITTER — INOPERATIVE (OIL PRESSURE) · airframe 75,329 hrs · 27,093 cycles

AFTER BRAKE RELEASE, WHILE SETTING MAX POWER, NUMBER ONE ENGINE OIL PRESSURE ROSE TO 60 PSI. REMOVED AND REPLACED PRESSURE TRANSMITTER IAW MM 79-32-1. ACCOMPLISHED ENGINE RUN UP IAW ARROW AIR J/C 72-000-30-02

Part: WIRE — DAMAGED (ANTI SKID SYS) · airframe 74,939 hrs · 26,905 cycles

ON FINAL ANTI-SKID LIGHT STAYED ON WITH LFI INDICATION. CHECKED ANTI-SKID WIRING IAW W/D 32-3-0. FOUND BROKEN WIRE GOING TO LT IN-BOUND VALVE, REPAIRED WIRE IN ACCORDANCE WITH MM 20-50-1, OPERATIONAL CHECKED ANTI-SKID SYSTEM IAW MM 32-43-0. OPERATIONAL CHECKED NORMAL. ANTI-SKID SYSTEM CHECKED NORMAL IAW MM 32-43-0.

Part: LINE — LEAKING (ENGINE OIL) · airframe 74,665 hrs · 26,821 cycles

NR 2 ENGINE PRECAUTIONARY SHUTDOWN DUE TO FLUCTUATING OIL PRESSURE AND INTERMITTENT PRESSURE WARNING LIGHT AT 1555Z WINDMILLING OIL PRESSURE 15-25 PSI. INSPECTED NR 2 ENGINE, FOUND RIGID LINE BETWEEN MAIN OIL FILTER AND DIFFERENTIAL PRESSURE SWITCH DAMAGED (LEAKING). REMOVED AND REPLACED RIGID LINE IAW DC8 MM 20-12-0 AND 79-20-6. OPERATIONS CHECK NORMAL IAW MM 71-00. NO LEAKS FOUND. ALSO NR 2 ENGINE MAIN OIL FILTER WAS INSPECTED IAW DC8 MM 79-20-7; NO CONTAMINATION FOUND.

Part: SPAR CAP · airframe 74,553 hrs · 26,763 cycles

LOG PAGE # 503179. DISCREPANCY: DURING 1A CHECK THE FOLLOWING WAS FOUND; ITEM # 128M: L/H WING AUXILIARY SPAR INBD. UPPER LOG WITH CRACK. GENERATED BY J/C # 51-020-04-06-1. CORRECTIVE ACTION: ACCOMPLISHED TEMPORARY REPAIR IN ACCORDANCE WITH BOEING MESSAGE INW-LIM-03-00004H, DATED 01/03/02. APPROVAL FOR THE REPAIR WAS GRANTED ON 8110-3. REPETITIVE INSPECTION UNTIL REPLACEMENT IS PART OF THE APPROVAL.

Part: GYRO — FAILED (COCKPIT) · airframe 74,218 hrs · 26,629 cycles

FIRST OFFICER'S COMPASS FLAG IN VIEW; FIRST OFFICER'S HORIZONTAL INDICATOR (HSI) CAPTAIN'S RADIO MAGNETIC INDICATOR (RMI). REMOVED AND REPLACED NR 1 DIRECTIONAL GYRO IAW MM 34-21-1. ALSO REMOVED AND REPLACED CIRCUIT BREAKER 2 AMP IAW MM 20-50-1. PERFORMED OPS CHECKED IIASW MM 34-21-0 FOUND NORMAL.

Part: CAP — LOOSE (NR 4 ENGINE) · airframe 74,155 hrs · 26,602 cycles

NR 4 ENGINE OIL QUANTITY DROPPED TO ZERO. PRECAUTIONARY SHUT DOWN: N1 26 PERCENT, N2 35 PERCENT, OIL TEMP 90C. INSPECTED NR 4 ENGINE AND FOUND CSD SPLINE STAND PIPE CAP LOOSE, RE-TIGHTENED CAP IAW MM 79-20-6. SERVICED ENGINE OIL IAW 12-20-1 RAN ENGINE PER 71-00, NO LINES NOTICED. INSPECTED MAIN OIL FILTER FOR CONTAMINATION IAW MM 79-20-7, NO CONTAMINATION FOUND. LEAKS CHECK PER 71-00 FOUND NORMAL.

Part: FIRE DETECTOR — MALFUNCTIONED (NR 4 ENGINE) · airframe 74,028 hrs · 26,550 cycles

NR 4 ENGINE FIRE WARNING ILLUMINATED IN FLIGHT. OVERWEIGHT LANDING AT 277.0 LBS PERFORMED. REMOVED AND REPLACED NR 4 FIRE SENSOR ON BURNED SECTION OF THE ENGINE IAW MM 26-10-1. ALSO REWIRED FROM PL-1341 CONNECTOR TO PL- 1368, PL-1367 CONNECTOR AND REPLACED CONNECTORS PL-1368 AND PL-1367. NEEDS OPS CHECK. ACCOMPLISHED SPECIAL STRUCTURAL "A" INSPECTION IAW ARROW AIR DC-8 MM, VOLUME I, 60 SERIES PAGES 5-4-8 TO 5-4-16 NO VISUAL DEFECTS NOTED. REMOVED AND REPLACED NR 4 FIRE DETECTOR SENSOR UPPER FORWARD IAW 26-10-1. OPS CHECKED NORMAL ON GROUND. SYSTEM ENGINE TEST NORMAL IAW MM 2-6-10.

Part: LINE — LEAKING (COMPRESSOR BRG) · airframe 73,985 hrs · 26,535 cycles

CLIMB FL 270 NR 2 ENGINE OIL PRESSURE FLUCTUATED BELOW 35 PSI, OIL PRESS LIGHT CAME ON, OIL TEMPERATURE WENT UP. FOLLOWED ENGINE SHUT DOWN PROCEDURES. 15 PSI OIL PRESS FOR 30 MINUTES. AIRCRAFT LANDED OVERWEIGHT WITHOUT INCIDENT. INSPECTED NR 2 ENGINE FOR EVIDENCE OF OIL LEAK, FOUND BOTH SEALS DAMAGED BETWEEN MAIN OIL FILTER TO COMPRESSOR INTERMEDIATE BEARING TUBE. REMOVED AND REPLACED TUBE ASSY AND SEALS AS REQUIRED IAW MM 79-20-6, OPS CK NORMAL IAW 71-00 NO LEAKS FOUND. ALSO INSPECTED MAIN OIL FILTER, NO METAL PARTICLES FOUND, REMOVED AND REPLACED MAIN OIL FILTER IAW DC8 MM 79-20-7, NO DEFECTS NOTED. SERVICE OIL TANK IAW DC8 MM 12-20-1. PERFORMED OVERWEIGHT LANDING INSPECTION IAW ARROW AIR DC8 MM VOL1 PAGES 5-

Part: COMPUTER — MALFUNCTIONED (STAB CONTROL) · airframe 73,913 hrs · 26,511 cycles

DURING DESCEND PITCH TRIM COMPENSATOR FAILED IN EXTENDED POSITION, PERFORMED EMERGENCY CHECKLIST PHASE 1 AND 2 ITEMS; INITIATED A FLAP 50 LANDING AND DECLARED AN EMERGENCY IAW PHASE 2 EMERGENCY ABNORMAL CHECKLIST. REMOVED AND REPLACED PITCH COMPUTER IAW MM 27-30-12 SYSTEMS OPERATIONS AND LEAKS CHECKED NORMAL IAW MM 24-30-6 AND MM 34-11-0. AIRCRAFT RETURN TO SERVICE.

Part: OIL SYSTEM — LACK OF LUBE (NR 3 ENGINE) · airframe 73,815 hrs · 26,481 cycles

NR 3 ENGINE OIL QUANTITY INDICATING ZERO; WITH OIL PRESSURE FLUCTUATING AND LOW OIL PRESSURE, LIGHT ILLUMINATED. PERFORMED IN-FLIGHT ENGINE SHUTDOWN AT 1920Z. NOTE WINDMILLING OIL PRESSURE 20 PSI TURNED ON START LEVER AT 2020Z AS PER AFM. SERVICED NR 3 ENGINE OIL TANK WITH 17 QUARTS OF 2380 OIL. IDLE RAN NR 3 ENGINE, NO LEAKS NOTED. SERVICED TWO MORE QUARTS AFTER ENGINE SHUTDOWN. ACCOMPLISHED ENGINE RUN CHECK IAW MM 71-00 AND PERFORMED OPS CHECK OF OIL SYSTEM IAW MM 79-00, NO LEAKS NOTED ENGINE OPERATION NORMAL.

Part: ENGINE — POWER LOSS (NR 4) · airframe 73,722 hrs · 26,450 cycles

AFTER BRAKE RELEASE, LOST PARTIAL POWER ON NR 4 ENGINE. ABORTED TAKEOFF AND RETURNED TO RAMP. REMOVED AND REPLACED NR 4 ENGINE, OPS CHECK AND LEAK CHECK NORMAL. AIRCRAFT RETURNED TO SERVICE.

Part: HYDRAULIC LINE — BLOWN (LT MLG) · airframe 73,698 hrs · 26,438 cycles

LOST ALL HYDRAULIC ON LANDING. CHECK HYDRAULIC QUANTITY AND TO BOC AT STANDARD PIPE. REPLACED BLOWN BRAKE HYDRAULIC LINE AT LT GEAR, SERVICED MAIN HYDRAULIC SYSTEM; RUN UP ENGINES AND CHECK HYDRAULIC PUMPS OFR OPS AND FOUND NORMAL. OPERATED ALL FLIGHT CONTROLS AND ALL NORMAL; NO HYDRAULIC LEAKS DETECTED IAW MM 20-12-0 AND MM 12-31-1. INSTALLED TEMP FLEX LINE LT GEAR.

Part: B-NUT — LOOSE (NR 4 ENGINE) · airframe 73,413 hrs · 26,343 cycles

ABORTED TAKEOFF DUE TO NR 4 ENGINE WOULD NOT GO TO MAX POWER. FOUND COMPRESSOR BLEED ACTUATOR TO CONTROL CLOSED TUBE B-NUT LOOSE; TIGHTENED B-NUT IAW MM 75-30-2; PERFORMED FLAG CHECK ENGINE RUN UP OPS CHECKED NORMAL IAW MM 75-30-3 AND 71-00 MAX TAKEOFF POWER (187).

Part: HYDRAULIC LINE — LEAKING (HYD SYSTEM) · airframe 72,939 hrs · 26,157 cycles

WHEN READY TO TAXI, HYDRAULIC QUANTITY GAUGE INDICATED LOSS OF FLUID, HYDRAULIC PRESSURE GAUGE INDICATED LOSS OF PRESS. ACCOMPLISHED APPROPRIATE CHECKLIST, RETURNED TO RAMP. REMOVED AND REPLACED HYDRAULIC PRESSURE LINE FROM NR 3 ENGINE HYDRAULIC PUMP, OPS CHECK AND LEAK CHECK NORMAL IAW MM 29-10-12. AIRCRAFT RETURNED TO SERVICE.

Part: ENGINE — MALFUNCTIONED (NR 4)

WITH THROTTLE SET FOR MAX TAKEOFF NR 4 ENGINE GOT UP TO 1.70 EPR, N1-100, N2-100, AND THROTTLE FULL FORWARD. TAKEOFF ABORTED AND RETURNED TO THE RAMP.

Part: FUSE — BLOWN (SPOILER SYS) · airframe 72,844 hrs · 26,112 cycles

IN CRUISE NR 1 MAIN & ALT TANK FUEL BOOST PUMPS POPPED C/B'S, WITH ASSOCIATED INDICATION OF NR 1 & 2 CSD TEMP INOP, NR 1 & 2 ENGINE OIL TEMP AND QTY INOP, GEAR LIGHTS INOP AND SPOILER PRESS ZERO, WITH OVERRIDE POSITION INOP. ALL OTHER C/B'S CHECK NORMAL AND NO POWER BUS FAILURE LIGHT. ABNORMAL CHECKLIST COMPLIED WITH, DIVERTED FROM GUA TO SAL WITHOUT INCIDENT. REMOVED AND REPLACED SPOILER PUMP FUSES, SPOILER CHECK NORMAL IAW MM 27-62-0. PERFORMED COMPLETE ELECTRICAL SYSTEM CHECK AND FOUND NORMAL IAW MM 24-20-0. AIRCRAFT RETURNED TO SERVICE.

Part: SWITCH · airframe 72,692 hrs · 26,034 cycles

LOG PAGE 107381. DISCREPANCY: TAKE OFF WARNING HORN SOUNDS WHEN POWER ADVANCED WITH FLAP SETTINGS 12, 18, AND 23 DEGREES FOR TAKE OFF. CORRECTIVE ACTION: REMOVED AND REPLACED RIGHT HAND SPOILER RELAY SWITCH IAW MM 27-63-1 OPERATIONAL CHECK NORMAL IAW MM 27-63-0. AIRCRAFT RETURNED TO SERVICE.

Part: PRESSURE SWITCH · airframe 72,657 hrs · 26,015 cycles

LOG PAGE 109685. DISCREPANCY: AFTER TAKE OFF ENGINE #3 OIL PRESS LIGHT CAME ON, OIL PRESS 50 Psi, PRESS 40 Psi WITH POWER LEVER @ IDLE, OIL TEMP INCREASED TO 128 C ENGINE SHUT DOWN IAW AOM ABNORMAL PROCEDURE. ENGINE SHUT DOWN AT 2352Z. AIRCRAFT RETURNED TO KMIA AND PERFORMED OVERWEIGHT LANDING 279,000 Lbs. CORRECTIVE ACTION: REMOVED AND REPLACED DIFFERENTIAL PRESS SWITCH IAW MM 79-33-1 PERFORMED ENGINE RUN UP AND FOUND NORMAL IAW MM 71-00. ACCOMPLISHED OVERWEIGHT LANDING INSPECTION IAW J/C 6372 NO DEFECTS NOTED. AIRCRAFT RETURNED TO SERVICE.

Part: SWITCH — FAILED (SPOILER) · airframe 72,607 hrs · 25,986 cycles

LINE UP FOR TAKEOFF ADVANCED POWER AND GOT CONFIGURATION TAKEOFF WARNING HORN. AIRCRAFT RETURNED TO BLOCKS. REMOVED AND REPLACED RT SPOILER SWITCH IAW MM 27-63-01, OPS CHECK NORMAL IAW MM 27-63-00. AIRCRAFT RETURNED TO SERVICE.

Part: WIRE — DAMAGED (LANDING GEAR) · airframe 72,519 hrs · 25,947 cycles

UPON ENTERING A/C LANDING GEAR UNSAFE LIGHT ILLUMINATED. REPAIRED WIRE IAW MM 20-50-1. OPS CHECK GOOD IAW MM 33-41-0.

Part: CONTROL BOX — FAULTY (ANTI- SKID SYS)

ON TAKEOFF ROLL ANTI-SKID LIGHT ILLUMINATED ON SKID CONTROL MONITOR, RF2 AND LF1 LIGHTS WERE ON. ABORTED TAKEOFF AT 65 KNOTS. AIRCRAFT RETURNED TO BLOCKS. REMOVED AND REPLACED ANTI-SKID CONTROL BOX IAW 32-43-6. OPS CHECK NORMAL IAW MM 32-43-0. AIRCRAFT RETURNED TO SERVICE.

Part: SWITCH · airframe 72,263 hrs · 25,854 cycles

LOG PAGE 106071. DISCREPANCY: L/H MAIN LANDING GEAR DOWN INDICATOR INOP DURING LANDING ROLL. CHECKLIST ACCOMPLISHED. AIRCRAFT LANDED WITHOUT INCIDENT. CORRECTIVE ACTION: REPLACED L/H MAIN LANDING GEAR DOWN LOCK SWITCH AND CONNECTOR AND ACCOMPLISHED ALL REQUIRED TESTS ON LANDING GEAR INDICATION SYSTEM IAW MM 32-60-0 TEST GOOD.

Part: FIRE LOOP — MALFUNCTIONED (NR 2 & 3 ENGINE) · airframe 71,914 hrs · 25,704 cycles

AT 10,000 FT MSL MASTER FIRE WARNING SOUNDED MOMENTARILY NR 2 FIRE HANDLE ILLUMINATED, APPROX 30 SECONDS LATER MASTER FIRE WARNING SOUNDED MOMENTARILY AGAIN AND NR 3 FIRE HANDLE ILLUMINATED. ENGINE SEVERE DAMAGE OR SEPARATION CHECKLIST INITIATED, ENGINE NR 1, 2, 3 FIRE WARNING TESTED OK AND NR 4 DID NOT. ON THE SECOND IDENTIFY ENGINE NR 1, 2, 4 TESTED OK AND NR 3 DID NOT. AIRCRAFT RETURNED TO MIAMI WITHOUT INCIDENT. OVERWEIGHT LANDING PERFORMED INTO MIAMI. PERFORMED NR 2 ENGINE ELECTRICAL WIRING CHECK, FOUND NORMAL, FOR T/S REMOVED AND REPLACED NR 2 AMPLIFIER FIRE WARNING IAW MM 26-10-4 (WD 26-1-1). PERFORMED NR 3 ENGINE ELECTRICAL WIRING CHECK FOUND NORMAL IAW WD 26-1-1, FOR T/S REM.

Part: SPLICE — CRACKED (FUSELAGE) · airframe 71,894 hrs · 25,696 cycles

DURING MX CHECK NON-ROUTINE 93, AFT LOWER CARGO COMPARTMENT STA 980 LONGERON 22R, SPLICE WITH 4 INCH CRACKED. REMOVED SPLICE, FABRICATED NEW SPLICE IAW DOUGLAS DRAWING 3753235, PRIMED AND INSTALLED SPLICE IAW SRM 51-3-0 & SRM 51-1-20D.

Part: DOWNLOCK SWITCH — FAULTY (RT MLG) · airframe 71,612 hrs · 25,554 cycles

BEFORE LANDING WHEN LANDING GEAR LEVER SELECTED TO GEAR DOWN THE RIGHT LANDING GEAR GREEN LIGHT DID NOT ILUMINATE. LIGHT TOOK APPROX 2 MINUTES TO ILLUMINATE. AIRCRAFT LANDED WITHOUT INCIDENT. REMOVED AND REPLACED RIGHT MAIN LANDING GEAR DOWN AND LOCK SWITCH AND CANNON PLUG. LANDING GEAR OPERATIONAL CHECK PERFORMED ALL CKD NORMAL IAW MM 32-30-0 & 32-60-0.

Part: THRUST REVERSER — WORN (NR 4 ENGINE)

MIA - FLT 432 - ON PREFLIGHT, FOUND NR 4 ENGINE REVERSER DAMAGED. TROUBLESHOT AND FOUND THAT THE LOWER REVERSER TRACK FORWARD YOKE ASSY SEPARATED FROM ENGINE CASE. THIS CAUSED DAMAGE TO BOTH LEFT AND RIGHT AFT FAN AIR DUCTS, TAIL PIPE, RIGHT AND LEFT FIRE WALL SEAL AND BOTH LEFT AND RIGHT AFT COWLING. ENGINE WAS REMOVED AND ROUTED TO SHOP FOR REPAIR. MAIN CAUSE OF ALL DAMAGE WAS FAILURE OF THE LOWER TRACK FORWARD YOKE ASSY. ENGINE WAS RETURNED FROM SHOP. LOWER TRACK FORWARD YOUKE ASSY REPLACED, SYSTEM OPS NORMAL IAW MM 78-30-00. (M)

Part: CONTROL VLV — FAILED (TE FLAPS)

SJO - FLT 521 - WITH FLAPS SELECTED TO 23 DEGREES, LEFT FLAP INDICATED 23 DEGREES, RIGHT FLAP INDICATED 28 DEGREES. A/C ROLLED TO THE LEFT. WITH FLAPS SELECTED TO 35 DEGREES, LEFT FLAP INDICATED 35 DEGREES, RT FLAP INDICATED 42 DEGREES. A/C ROLLED RATE INCREASED TO THE LEFT, ON GROUND FLAPS INDICATED NORMAL IN ALL POSITIONS. REMOVED AND REPLACED FLAP CONTROL VALVE AND RIGGED IAW DACO MM. OPS CHECK OK. (M)

Part: SWITCH — FAILED (NR 3 ENGINE)

PTY - FLT 618 - NR 3 ENGINE OIL QTY DOWN TO 1 GALLON. DIVERTED TO MPTO. LANDED WITH NO FURTHER INCIDENT. FOUND LEAK. REMOVED AND REPLACED DIFFERENTIAL PRESS SWITCH IAW 79-31-00. NO LEAKS NOTED. (M)

Part: O-RING — FAILED (SLOT CONTL VLV)

POS - FLT 602 - AT TOP OF DESCENT, AIL AND RUDDER MANUAL REVERSION LIGHTS CAME ON. SYSTEM PRESSURE DROPPED TO ZERO AND FLUID QUANTITY WAS AT STANDPIPE LEVEL. EMERGENCY PROCEDURES WERE FOLLOWED. AIRCRAFT LANDED AT POS WITHOUT INCIDENT. REMOVED AND REPLACED SLOT CONTROL VALVE O-RING OPS NORMAL IAW MM 27-80-4. (M)

Part: BALLAST — FAILED (COCKPIT)

MIA - FLT 501 - UPON DESCENT INTO MIAMI, NOXIOUS ODORS ENTERED COCKPIT. CREW ON OXYGEN AND RAN CHECKLIST. UNABLE TO PINPOINT SOURCE OF ODOR. MAINTENANCE REMOVED AND REPLACED GLARESHIELD FLOURSCENT LIGHTING BALLAST. OPS CHECKED IAW MM 33-13-00. (M)

Part: LINE — FAILED (HYD SYSTEM)

SJU - FLT 760 - IN CRUISE QTY DROPPED TO HALFWAY ON QTY GAUGE, FOLLOWED BY AN ODOR OF HYDRAULIC FLUID (NOXIOUS). INVESTIGATION REVEALED FLUID ESCAPING FROM CARGO DOOR SWIVEL JOINT. REMOVED AND REPLACED SWIVEL AND AUX PUMP PRESSURE LINE. OPS CHECK OK IAW MM 29-20-2, 52-36-1 AND 20-60-0. (M)

Part: SWIVEL JOINT — LEAKING (HYD SYSTEM)

SJU - FLT 760 - IN FLIGHT EMERGENCY DECLARED IN CRUISE HYD QTY DROPPED TO HALFWAY ON QTY GAUGE, FOLLOWED BY AN ODOR OF HYD FLUID (NOXIOUS). AIRCRAFT LANDED IN MIAMI WITHOUT INCIDENT. INVESTIGATION REVEALED FLUID ESCAPING FROM CARGO DOOR SWIVEL JOINT. REMOVED AND REPLACED SWIVEL AND AUX PUMP PRESSURE LINE. OPS CHECK OK IAW MM 29-20-2, 52-38-1 AND 20-60-0. (M)

Part: INDICATOR — FAILED (COCKPIT)

MIA - FLT 510 - DURING CLIMB-OUT, RADAR QUIT WORKING. RETURNED TO MIAMI WITHOUT INCIDENT. REMOVED AND REPLACED RADAR INDICATOR, ANTENNA, AND R/T UNIT. SYSTEM OPS OK ON THE GROUND PER MM 34-42-0. REF: OPER CONTROL NR 98ZZZX562 AND 98ZZZX563. (X)

Part: ANTENNA — FAILED (COCKPIT)

MIA - FLT 510 - DURING CLIMB-OUT, RADAR QUIT WORKING. RETURNED TO MIAMI WITHOUT INCIDENT. REMOVED AND REPLACED RADAR INDICATOR, ANTENNA, AND R/T UNIT. SYSTEM OPS OK ON THE GROUND PER MM 34-42-0. REF: OPER CONTROL NR ARWA990201 AND 98ZZZX563.

Part: RT UNIT — FAILED (COCKPIT)

MIA - FLT 510 - DURING CLIMB-OUT, RADAR QUIT WORKING. RETURNED TO MIAMI WITHOUT INCIDENT. REMOVED AND REPLACED RADAR INDICATOR, ANTENNA, AND R/T UNIT. SYSTEM OPS OK ON THE GROUND PER MM 34-42-0. REF: OPER CONTROL NR ARWA990201 AND 98ZZZX562.

Part: RADAR — INOPERATIVE (COCKPIT)

MIA - FLT 510 - FLIGHT EN ROUTE ATL TO SJU DIVERTED TO MIA DUE TO WEATHER RADAR INOPERATIVE. REMOVED AND REPLACED RADAR R/T. OPS CHECK OK PER MM 34-42-0. (X)

Part: CABLE — BROKEN (NR 4 ENGINE)

MIA - FLT 747 - NR 4 ENGINE SHUT OFF VALVE, CABLE BROKEN. FABRICATED CABLE ASSY IAW MM 91-10-45. INSTALLED CABLE ASSY IAW MM 28-22-7 AS CHECKED NORMAL IAW MM 38-27-7. (M)

Part: HEAT — INOPERATIVE (PITOT)

SJU - FLT 759 - GROUND TURN BACK, F/O'S PITOT HEAT INOP. REMOVED AND REPLACED PITOT TUBE ASSY. OPS NORMAL IAW MM 30-30-0. SATISFACTORY LEAK CHECK IAW MM 34-12-0. (M)

Part: BUSS PANEL — FAILED (COCKPIT)

WHILE PERFORMING PRE-FLIGHT, COCKPIT FILLED WITH SMOKE. POWER SHUT DOWN, PROBLEM FOUND TO BE, SHORTED BUSS PROTECTION PANEL AND ASSOCIATED WIRING. REMOVED AND REPLACED BUSS PROTECTION PANEL AND BURNT WIRING SYSTEM; TESTED IAW MM 24-20-7. FOUND NOTE: SWISPORT GPU NR 350 IN USE AT THE TIME OF PROBLEM FOUND OK, TO HAVE FLUCTUATING VOLTS AND FREQUENCY.

Part: BALLAST — FAILED (CABIN)

SMELL OF ELECTRICAL INSULATION BURNING AFTER LANDING. REMOVED AND REPLACED BALLAST ASSY, OPERATION CHECKED NORMAL IAW MM 33-00-0.

Part: RELIEF VALVE — INOPERATIVE (NR 1 ENGINE)

AT 20:25 NR 1 LOW OIL PRESSURE LIGHT CAME ON 35 PSI ENGINE SHUT DOWN, TEMP 105. REMOVED AND REPLACED NR 1 ENGINE MAIN OIL FILTER AND OIL PRESS RELIEF VALVE, OPS CHECKED NORMAL IAW MM 11-00-0, 79-20-5, AND 79-20-7.

Part: ENGINE — FAILED (NR 1)

DURING CRUISE, NR 1 OIL PRESS LIGHT FLASHED INTERMITTENTLY, OIL PRESS OSCILATED BETWEEN 25-48 PSI, OIL TEMP ROSE TO 125 C, OIL QUANTITY INDICATED 2 GALS, N1 N2 READ NORMAL. PERFORMED PRECAUTION BY SHUT DOWN AS PER ABNORMAL IN FLIGHT ENG SHUT DOWN. REMOVED AND REPLACED NR 1 ENGINE, OPS AND LEAK CHECKED NORMAL IAW ARROW AIR J/C 6519 AND ARROW AIR J/C 6527 AND M/M 72-00.

Part: CLAMP — LOOSE (NR 1 TURBO COMP)

RETURNED TO LCK DUE LOSS OF PRESSURIZATION DUCTING. UNABLE TO HOLD CABIN. FOUND LOOSE DUCT CLAMP ON NR 1 TURBO COMPRESSURE INLET. REINSTALLED AND SAFETIED CLAMP, OPS NORMAL IAW MM 21-10-00.

Part: BOLT — LACK OF LUBE (RT MLG LATCH)

AFTER T/O AND GEAR RETRACTED, DOOR NOT LATCH LIGHT REMAINED ON. RAN CHECKLIST, NO HELP. RETURNED TO MIA. FOUND BROKEN WIRE AT LEFT LANDING GEAR DOOR SW AND FROZEN BOLT AT RT MAIN GEAR LATCH ASSY. REPAIRED WIRE IAW 20-50-0 AND CLEAN AND LUBRICATED BOLT IAW 20-10-0, OPS CK NORMAL IAW 32-31-4.

Part: EGT INDICATOR — FAILED (COCKPIT)

WHEN LEAVING FL 280 FOR FL 310, NR 2 EGT IND STAYED AT 500, EVEN AFTER REACHING FL 310 AND RETARDING THROTTLE. PRECAUTIONARY SHUTDOWN OF NR 2 ENG, TIME 09207, OIL PRESS AT 24 PSI WINDMILLING, CLEARED SHORT AT LOWER ATT JUNCTION BLOCK BY CLEANING JUNCTION BLOCK. REMOVED AND REPLACED EGT INDICATOR (2) AND CHECKED WITH BARFIELD EGT TEST SET, OPS CKC GOOD ON ENGINE RUN-UP IAW M/M 77-20-00.

Part: BATTERY PACK — DISCHARGED (CABIN)

EMERGENCY LIGHTS DISARM SWITCH WILL NOT DISARM. REMOVED AND REPLACED EMERGENCY LIGHT BATTERY PACK, SYSTEM OPS CHECKED NORMAL IAW 33-50-00.

Part: LIFT TRANSDUCER — INOPERATIVE (RT WING)

ON TAKEOFF, STALL SHAKER CAME ON, TWICE. ABORTED TAKEOFF AT 298,000 LBS. REMOVED AND REPLACED LIFT TRANSDUCER PER MM 34-16-0. ADJUSTMENT TEST 501, CODE 2, UNABLE TO DUPLICATE FAIL, FOUND NORMAL. PERFORMED OVERWEIGHT LANDING INSP, NO STRUCTURAL DEFECTS NOTED.

Part: OIL PRESS SWITCH — MALFUNCTIONED (NR 2 ENGINE)

NR 2 ENGINE OIL PRESSURE LIGHT CAME ON. RETARDED THROTTLE, LIGHT STAYED ON. SHUT DOWN ENGINE AS PER ABNORMAL CHECKLIST, TIME 1430Z, OIL PRESSURE 24 PSI. REMOVED AND REPLACED MAIN OIL FILTER, OLD ONE FOUND NORMAL. PRECAUTIONARY REMOVED AND REPLACED DIFFERENTIAL OIL PRESSURE SW, PRESSURE LIGHT SW EINGINE RUN-UP OIL PRESSURE AND TEMP CHECKED NORMAL PER MM 79-20-7, 79-32-2 AND 79-33-1.

Part: GENERATOR — MISWIRED (NR 2)

ON TAXI OUT NR 2 GENERATOR FIELD RELAY TRIPPED. STRONG BURNING SMELL IN COCKPIT BEHIND ELECTRICAL CONTROL PANEL BULKHEAD. DISCONNECTED NR 2 GENERATOR CSD AND RETURNED TO BLOCK. NO FIRE NOTED. TROUBLESHOOTING REVEALED A WIRING PROBLEM AT NR 2 GENERATOR, CAUSING THE GENERATOR CONTROL UNIT IN THE COCKPIT TO OVERHEAT AND FAIL. WIRING AT THE GENERATOR WAS REPAIRED, GCU CHANGED AND SYSTEM OPERATED NORMAL. THE GCU CAUSED THE SMOKE.

Part: CLAMP — LOOSE (TURBO COMPRESSOR)

DURING FLIGHT FROM SJU, COULD ONLY PRESSURIZE AIRCRAFT AT TO 5.0PSI DIFFERENTIAL, WITH ALL T.C.'S RUNNING AND OUTFLOW CLOSED. CABIN CONTINUED TO CLIMB TO F.L.16.0 AFTER LEVEL OFF AT F.L. 29.0. AIRCRAFT DIVERTED TO MIA WITHOUT INCIDENT. FOUND CONNECTOR CLAMP AT NR 1 AND NR 2 T/C DELIVERY DUCT TO MIXING VALVE DISCONNECTED. RECONNECTED CONNECTORS, PRESSURIZED AIRCRAFT, OPS CHECKED NORMAL, 8PSI DIFFERENTIAL.

Part: O-RING — DAMAGED (RUDDER CONTL)

INFLIGHT AT FL 350, HYDRAULIC QUANTITY SUDDENLY STARTED DESCENDING AND CONTINUED DESCENDING. ISOLATED HYDRAULIC SYSTEM. RETURNED TO MIAMI AND FOUND RUDDER SELECTOR VALVE PLUG LEAKING. REPLACED O-RING, NO LEAKS NOTED IAW DC-8 MM 29-00-00.

Part: SWITCH — INOPERATIVE (RT MLG)

ON CLIMB-OUT FROM ATL, GEAR NOT LATCHED. LIGHT CAME ON, RECYCLED GEAR AND NOW GEAR AND DOOR LIGHT ON. DIVERTED TO MIAMI. TROUBLESHOT, FOUND RT MLG UPLATCH SWITCH BAD. REMOVED AND REPLACED SWITCH I.A.W. 32-30-00. OPS CHECKED NORMAL ON GEAR SWING, RETURN ACFT TO SERVICE.

Part: ANGLE — CORRODED (BS 280/340)

LEVELS 1 AND 2 CORROSION AT INNER SURFACE STA 340 AND 280, LONGERONS 31L AND 26L. ATTACHMENT ANGLE WAS REMOVED AND REPLACED. FABRICATED ANGLE IAW DC-8 SRM 53-4-1 AND 51-1-4. TREATED AND INSTALLED IAW DC-8 SRM 51-1-8 AND 51-1-20D.

Part: PRESS DOME — CORRODED (LEFT)

LT DOME WITH EXFOLIATE CORROSION ON LOWER INNER RADIUS. REMOVED AND REPLACED DOME PER DRAWING NR 9750428.

Part: TAIL CONE — CRACKED (AFT FUSELAGE)

TAIL CONE HAS CRACKS OF .5 AND 1.5 AT LONGERONS 7L AND 11L. REPAIRED CRACKS PER DC-8 SRM 53-2-0, FIG 1B, SHEET 3 AND 53-5-3, FIG 4, SHEETS 1 AND 2. CLEANED AND TREATED AREA PER DC-8 SRM 51-1-8.

Part: TRANSLATING RING — CRACKED (NR 3 ENGINE)

NR 3 ENGINE TRANSLATING RING HAS 2 INCH CRACK IN RT FORWARD UPPER STRINGER. REPAIRED UPPER STRINGER IAW DC-8 SRM 78-3-3.

Part: FITTING — CRACKED (BS 1160)

AFT CARGO COMPARTMENT HAS CORRODED AND BROKEN FITTING AT FS 1160, LONGERON 31R. REMOVED AND REPLACED FITTING PER DC-8 SRM 51-3-0.

Part: FITTING — CRACKED (BS 1220)

CRACKED FITTING AT FS 1220 BETWEEN CEILING AND FLOOR BEAM. CRACKED FITTING REMOVED AND REPLACED IAW DC-8 SRM 51-1-20D AND 51-1-21.

Part: PLATE — CORRODED (WS 22.75-50)

RIGHT WING INNER TOP PANEL PLATE SHOWS LEVEL 2 CORROSION FROM XRS 22.750 TO XRS 50.000. REPAIRED AND TREATED AREA PER DC-8 SRM 57-2-1 AND 51-1-8.

Part: GALLEY DOOR — CRACKED (BS 1220-1240)

AFT GALLEY DOOR AT LONGERON 21R, FS 1220 TO 1240 HAS 2.5 INCH CRACK. REPAIRED CRACK PER DC-8 SRM 53-2-0, FIG 2.

Part: FORMER — CRACKED (WS 766.25)

A 1 INCH CRACK FOUND ON RIGHT WING LEADING EDGE FORMER AT STA XFS 766.250. REPAIRED AREA IAW DRAWING ARW 015713-0304, FAA FORM 8110 APPROVED.

Part: PLATE — CORRODED (WS 50-74.869)

RT WING, INNER WING TOP PANEL PLATE SHOWS LEVEL 2 CORROSION FROM XRS 50.000 THROUGH XRS 74.869. REPAIRED WING TOP PANEL IAW DC-8 SRM 57-2-1, FIG 10, SHEET 2. TREATED AND INSTALLED DOUBLER IAW DC-8 SRM 51-1-8, 51-1-17 AND 51-1-20D.

Part: SKIN — CORRODED (BS 1540-1723)

LEVEL 1 CORROSION, SEVERAL SPOTS AT FUSELAGE AFT SECTION, FS 1540 TO FS 1723.

Part: SKIN — CORRODED (FS 920)

WING CENTER SECTION HAS LEVEL 2 CORROSION BETWEEN SKIN AND FILLER AT LONGERON 22L, FS 920 THROUGH 980. REPAIRED AREA ACCORDING TO DACO ROD SKETCH NR 96-05-20-003.

Part: FLOOR BEAM — CORRODED (BS 1723)

SUPPORT ANGLE AT FLOOR BEAM HAS LEVEL 2 CORROSION AT FS 1723. REMOVED ANGLE, FABRICATED, TREATED AND INSTALLED ANGLE IAW DC-8 SRM 53-7-3, 51-1-4, 51-1-8 AND 51-1-21.

Part: SKIN — DAMAGED (RT TE FLAP)

TEMPORARY REPAIR ON RIGHT WING INBOARD FLAP AT STA XW 60.000. INSTALLED PERMANENT REPAIR PER DC-8 SRM 57-2-1, FIG 2Q. WING INBOARD FLAP PLATING CLEANED, TREATED AREA PER DC-8 SRM 51-1-8.

Part: TRACK — CRACKED (RT WING)

RIGHT WING FLAP, NR 3 HINGE SLIDING COVER EXTERIOR TRACK IS BROKEN IN 2 PLACES. BROKEN TRACK REMOVED AND REPLACED IAW DC-8 MM 27-51-3.

Part: SKIN — CORRODED (BS 150-190)

FORWARD CARGO COMPARTMENT HAS LEVEL 2 CORROSION FROM FS 150 TO 190 AT LONGERON 31R. FORMED STRAP AND TREATED AND INSTALLED PER DC-8 SRM 53-4-1, 51-1-4, 51-1-8 AND 51-1-21.

Part: LONGERON — CRACKED (RT FUSELAGE)

A 9.5 CRACK STOP HOLE, OLD REPAIR HAS EXTENDED 3 FORWARD ON LONGERON 24R. REMOVED AND REPLACED LONGERON 24R PER DOUGLAS DRAWING 5750198 AND 5615475.

Part: FORMER — CRACKED (WS 347.75)

A 1 INCH CRACK FOUND IN RIGHT WING LEADING EDGE FORMER AT STA XFS 347.750. REPAIRED AREA IAW DRAWING ARW 015713-0309, FAA FORM 8110 APPROVED.

Part: TRANSLATING RING — CRACKED (NR 3 ENG TR)

NR 3 ENGINE TRANSLATING RING, AFT UPPER CORNER IS CRACKED. REPAIRED IAW ARROW AIR DRAWING NR ARW 015713-1182, FAA 8110-APPROVED.

Part: TRAPEZOID FTG — CRACKED (RT MLG)

RT MLG FITTING ASSEMBLY TO FUSELAGE, TRAPEZOID SHOWS 3 INCH CRACK AT 9, 10 AND 3 O'CLOCK. TRAPEZOID FITTING WAS REMOVED AND REPLACED IAW DC-8 SRM 51-1-21, 51-1-20D AND 51-3-0 AND DOUGLAS TRAP FITTING REPLACEMENT GUIDE.

Part: FORMER — CRACKED (WS 766.25)

CRACK AT LT WING LEADING EDGE FORMER AT XFS 766.250. REPAIRED AREA IN ACCORDANCE WITH CF DRAWING CF-N441J-16/96, FAA 8110-APPROVED.

Part: FRAME — BROKEN (BS 1560)

LT UPPER SURFACE CUSP EXTRUSION HAS BROKEN FRAME AT LONGERON 21L, FS 1560. REPAIRED FRAME IN ACCORDANCE WITH DC-8 SRM 57-2-0.

Part: FITTING — CORRODED (BS 440-460)

FORWARD CARGO COMPARTMENT HAS LEVEL 2 CORROSION BETWEEN FS 440 TO 460 AT LONGERON 31L. REMOVED AND REPLACED FITTING PER DC-8 SRM 51-1-20D AND 51-1-17.

Part: DOUBLER — CORRODED (BS 400-450)

FORWARD CARGO COMPARTMENT HAS LEVEL 2 CORROSION AT LONGERON 31R, FS 400 THROUGH 450. REPLACED EXTRUSION AND DOUBLER PER DC-8 SRM 53-2-1, FIG 7, SHEET 1 AND 53-4-1. CLEANED AND TREATED AREA PER DC-8 SRM 51-1-8.

Part: FITTING — CRACKED (FS 1220)

AFT CARGO COMPARTMENT HAS BROKEN FITTING AT LONGERON 31R AT FS 1220. REMOVED AND REPLACED FITTING PER DC-8 SRM 51-3-0.

Part: DOOR — CRACKED (TAIL CONE)

TAIL CONE ACCESS DOOR NR 62 FS 19010 CRACKED .5 INCH AT LOWER PART. REPAIRED AREA PER DRAWING OF N441J-15/96, DER APPROVED.

Part: HINGE — CRACKED (NLG DOOR)

NLG LEFT FORWARD DOOR HINGE AFTER WEB CRACKED. REPAIRED IN ACCORDANCE WITH FAUCETT DRAWING, FAA 8110-APPROVED.

Part: FILLET — BROKEN (LT TE SLOT)

LEFT WING OUTBOARD SLOT UPPER PART WITH BROKEN FILLET. REMOVED AND REPLACED SEAL AND SPRING IN ACCORDANCE WITH DC-8 MM 27-80-1.

Part: FORMER — CRACKED (WS 766.25)

A 2 INCH CRACK AT LT WING LEADING EDGE FORMER AT XFS 766.250. REPAIRED AREA IN ACCORDANCE WITH CF DRAWING CF-N441J-16/96, FAA 8110-APPROVED.

Part: FITTING — CORRODED (BS 1240-1260)

AFT LOWER CARGO COMPARTMENT HAS LEVEL 2 CORROSION AT FITTING, FS 1240 THROUGH 1260, LONGERONS 33R AND 34R. FITTING WAS REMOVED AND REPLACED PER DC-8 SRM 51-30.

Part: LONGERON — CRACKED (BS 180)

FORWARD CARGO COMPARTMENT AT LONGERON 30R, FS 180, CRACKED 2 INCHES. CRACKED SECTION REMOVED AND REPLACED WITH EXTRUSION PER DC-8 SRM 51-1-8 AND 51-1-20D.

Part: HINGE — CRACKED (NLG DOOR)

NLG RIGHT FORWARD DOOR HINGE AFTER WEB CRACKED. REPAIRED IN ACCORDANCE WITH FAUCETT DRAWING, FAA 8110-APPROVED.

Part: LONGERON — CORRODED (BS 500)

FORWARD DECK, LONGERONS 35R AND 36 AT FS 500 HAVE LEVEL 2 CORROSION UNDER FRAME. REPAIRED AREA PER DC-8 SRM 51-1-21, 53-2-0, 51-1-8 AND 51-1-20D.

Part: FRAME — CORRODED (BS 1000)

AFT CARGO COMPARTMENT HAS LEVEL 2 CORROSION AT FRAME UPPER CAP, FS 1000, LONGERONS 33R AND 34R. CORRODED CAP WAS REMOVED, FABRICATED, TREATED AND INSTALLED PER DC-8 SRM 53-4-1, 51-1-4, 51-1-8 AND 51-1-21.

Part: FRAME — CORRODED (BS 1324)

AFT CARGO COMPARTMENT HAS LEVEL 2 CORROSION ON SIDEWALL UPPER AND LOWER FRAMES AT STA 1324. FRAMES WERE REPAIRED, TREATED AND INSTALLED PER DC-8 SRM 53-4-1, 51-1-4 , 51-1-8 AND 51-1-20D.

Part: FITTING — CRACKED (BS 160)

FORWARD CARGO COMPARTMENT AT LONGERON 30R, FS 160, IS CRACKED 1 INCH. REPAIRED LONGERON 30R IN ACCORDANCE WITH DC-8 SRM 53-2-2, FIG 4A; 10. TREATED AND INSTALLED IAW DC-8 SRM 51-1-8 AND 51-1-20D.

Part: DOUBLER — CORRODED (BS 215)

FORWARD CARGO COMPARTMENT HAS LEVEL 2 CORROSION AT FS 215, LONGERON 31R DOUBLER. REMOVED AND REPLACED DOUBLER IAW DC-8 SRM 51-1-8 AND 53-2-0.

Part: DOOR FRAME — CORRODED (CARGO COMPT)

FORWARD CARGO COMPARTMENT NR 2 DOOR FRAME AT STA 560 HAS LEVEL 2 CORROSION. FRAME WAS REMOVED AND NEW FRAME FABRICATED IAW DC-8 SRM 52-4-1 AND 51-1-4. TREATED AND INSTALLED PER DC-8 SRM 51-1-8, 51-1-17 AND 51-1-21.

Part: DOUBLER — CORRODED (BS 180)

FORWARD CARGO COMPARTMENT HAS LEVEL 2 CORROSION AT FS 180, LONGERON 31R. REPLACED DOUBLER PER DC-8 SRM 51-1-21 AND 51-1-20D. CLEANED AND TREATED AREA PER DC-8 SRM 51-1-8.

Part: FORMER — CRACKED (WS 728.75)

CRACK AT LT WING LEADING EDGE FORMER AT XFS 728.750 THROUGH 747.500. REPAIRED AREA IN ACCORDANCE WITH CF DRAWING CFN441J-16/96, FAA 8110-APPROVED.

Part: FRAME — BENT (FUSELAGE)

LT UPPER SURFACE CUSP EXTRUSION, FRAME AT LONGERON 21L, IS BENT. REPAIRED FRAME IAW DC-8 SRM 53-2-0, FIG 2. FORMED REPAIR PARTS IAW DC-8 SRM 53-4-1, 51-1-4 AND CLEANED AND TREATED AREA IAW DC-8 SRM 51-1-8.

Part: FILLET — BROKEN (WS 289)

RIGHT WING UPPER SURFACE TRAILING EDGE HAS BROKEN FILLET AT STA XRS 289.000. FABRICATED FILLET IAW DC-8 SRM 57-3-3 AND 51-1-4. REMOVED AND REPLACED FILLET IAW DC-8 SRM 51-1-15.

Part: SKIN — CORRODED (BS 1160-1220)

LEVEL 2 CORROSION FOUND AT EXTERIOR UPPER SKIN C-3, UPPER DOOR JAMB, AT FS 1160 TO 1220. REMOVED CORRODED SKIN. FABRICATED AND TREATED DOUBLERS IAW ARROW AIR SKETCH AND DC-8 SRM 51-1-4 AND 51-1-8. INSTALLED PER DC-8 SRM 51-1-20D.

Part: ANGLE — CRACKED (NR 3 ENGINE)

NR 3 ENGINE TRANSLATING RING UPPER ANGLE CRACKED. REPAIRED IAW DRAWING ARW 015713-1184 FAA FORM 8110 APPROVED.

Part: FORMER — CRACKED (WS 733)

A 1 CRACK FOUND ON RIGHT WING LEADING EDGE FORMER AT STA XFS 733.000. REPAIRED AREA IAW DRAWING ARW 015713-0306, FAA FORM 8110 APPROVED.

Part: LONGERON — CORRODED (BS 960-980)

RIGHT WING CENTER SECTION AT STA 960 THROUGH 980, LONGERON 22R, HAS CORROSION, CRACKS AND SHEARED RIVETS. REPAIRED AREA ACCORDING TO DACO ROD SKETCH NR 96-05-20-003.

Part: ANGLE — CORRODED (FS 200)

FORWARD CARGO COMPARTMENT HAS LEVEL 2 CORROSION ON ANGLE AT LONGERON 31R AT FS 200. REMOVED ANGLE AND FABRICATED NEW ANGLE IAW DC-8 SRM 53-4-1 AND 51-1-4. TREATED AND INSTALLED ANGLE PER DC-8 SRM 51-1-8 AND 51-1-20D.

Part: SKIN — CRACKED (BS 55)

EXTERIOR FUSELAGE HAS 1 CRACK AT LONGERON 33R STA 55, C3 DOOR. REPAIRED AREA PER DRAWING ARW 015713-0315, DER APPROVED.

Part: FORMER — CRACKED (WS 845.5)

A .75 INCH CRACK FOUND ON RIGHT WING LEADING EDGE FORMER AT STA XFS 845.500. REPAIRED AREA IAW DRAWING ARW 015713-0303, FAA FORM 8110 APPROVED.

Part: FORMER — CRACKED (WS 324)

A 1 INCH CRACK FOUND ON RIGHT WING LEADING EDGE FORMER AT STA XFS 324.000. REPAIRED AREA IAW DRAWING ARW 015713-0310, FAA FORM 8110 APPROVED.

Part: LONGERON — CRACKED (BS 960)

LONGERON 24L HAS 3.5 INCH CRACK AT STA 960. LONGERON 24L WAS REPAIRED IAW DC-8 SRM 53-2-2, FIG 5. FABRICATED DOUBLERS PER DC-8 SRM 51-1-1. TREATED AND INSTALLED DOUBLERS IAW DC-8 SRM 51-1-8 AND 51-1-20D.

Part: DOOR BASE — CRACKED (EMER EXIT)

LEFT AFT EMERGENCY DOOR BASE HAS LEVEL 1 CORROSION AND 4 INCH CRACK AT LONGERON 21L. REMOVED CORROSION AND REPAIRED AREA PER DC-8 SRM 53-2-0, FIG 1B, SHEET 3 AND 51-1-8.

Part: FORMER — CRACKED (WS 747.5)

A .75 INCH CRACK ON RIGHT WING LEADING EDGE FORMER AT STA XFS 747.500. REPAIRED AREA IAW DRAWING ARW 015713-0305 FAA FORM 8110 APPROVED.

Part: CARGO DOOR — CRACKED (NR 3)

NR 3 LOWER CARGO DOOR HAS 1 INCH CRACK IN LEFT UPPER CORNER. REPAIRED NR 3 CARGO DOOR IAW DC-8 SRM 52-2-2 AND 52-4-1. FABRICATED AND TREATED DOUBLER IAW DC-8 SRM 51-1-4 AND 51-1-8. INSTALLED DC-8 IAW SRM 51-1-21.

Part: FITTING — CRACKED (FS 1160)

AFT CARGO COMPARTMENT, LOWER VERTICAL STRUT CRACKED AT LONGERON 27R AT FS 1160. REMOVED AND REPLACED NEW FITTING PER DC-8 SRM 51-3-0.

Part: PLATE — CRACKED (RT WINGS)

RIGHT WING, LOWER SURFACE, PYLON LATERAL REINFORCEMENT PLATE CRACKED. REMOVED CRACKED PLATE, FABRICATED NEW DOUBLER PER DC-8 SRM 54-3-3 AND 51-1-4. TREATED AND INSTALLED PER DC-8 SRM 51-1-8, 51-1-17 AND 51-1-21.

Part: FORMER — CRACKED (WS 723)

A 1 INCH CRACK ON RIGHT WING LEADING EDGE FORMER AT STA XFS 723.000. REPAIRED AREA IAW DRAWING ARW 015713-0307, FAA FORM 8110 APPROVED.

Part: FORMER — CRACKED (WS 852)

A 1 INCH CRACK FOUND ON RIGHT WING LEADING EDGE FORMER AT STA XFS 852. REPAIRED AREA IAW DRAWING ARW 015713-0302, FAA FORM 8110 APPROVED.

Part: FILLET — BROKEN (BS 940)

MAIN CARGO COMPARTMENT HAS LEVEL 2 CORROSION AT STA 940, RT UPPER PART, ALONG WITH BROKEN FILLET. REPAIRED AREA ACCORDING TO DACO ROD SKETCH NR 96-05-20-003.

Part: DOOR CUTOUT — DAMAGED (BS 280)

TEMPORARY REPAIR IN FORWARD LOWER CARGO COMPARTMENT DOOR CUTOUT, FORWARD CORNER, AT STA 280. REPAIRED FORWARD LOWER CORNER PER DC-8 SRM 53-2-0, FIG 22, CLEANED AND TREATED AREA PER DC-8 SRM 51-1-8.

Part: SKIN — CRACKED (BS 600-680)

PERMANENT REPAIR OF LOWER FUSELAGE AT LONGERON 36 FROM FS 600 TO 680 ACCOMPLISHED PER DRAWING ARW 015713-0013, FAA FORM 8110-APPROVED.

Part: DOOR HOUSING — CORRODED (FS 280-340)

FORWARD CARGO COMPARTMENT HAS LEVEL 2 CORROSION AT UPPER SURFACE AT DOOR HOUSING, FS 280 PLUS 340. REPAIRED UPPER SURFACE IAW DC-8 SRM 53-2-0, FIG 1D. FABRICATED DOUBLER IAW DC-8 SRM 53-4-1, 51-1-1. TREATED AND INSTALLED IAW DC-8 SRM 51-1-8, 51-1-20D.

Part: PRESS DOME — CRACKED (RIGHT)

RT DOME CRACKED AT LOWER INNER RADIUS. REMOVED AND REPLACED DOME PER DRAWING NR 9750428.

Part: FITTING — CRACKED (BS 780)

MAIN CARGO COMPARTMENT HAS 3 INCH CRACK IN FITTING AT STA 780, LONGERON 22L. REPAIRED AREA PER ROD SKETCH NR 96-04-25-007, DOUGLAS-APPROVED ACTION NR 296570. FABRICATED AND TREATED DOUBLER PER DC-8 SRM 51-1-4, 51-1-8. INSTALLED DOUBLER PER DC-8 SRM 51-3-0, 51-1-20D.

Part: PANEL — CORRODED (WS 22.75-50)

RT WING, INNER WING TOP PANEL PLATE SHOWS LEVEL 2 CORROSION FROM XRS 22.750 THROUGH XRS 50.000. REPAIRED WING TOP PANEL IAW DC-8 SRM 57-2-1, FIG 15. TREATED AND INSTALLED DOUBLER IAW DC-8 SRM 51-1-8, 51-1-17 AND 51-1-20D.

Part: B NUT — LOOSE (TURBINE CASE)

AIRCRAFT RETURNED TO MIA DUE TO LOSS OF OIL QUANTITY, NR 3 ENGINE. FOUND NR 6 BEARING FILTER B-NUT LOOSE, RESECURED AND SAFETIED. NO LEAKS NOTED ON RUN-UP -- RESERVICED OIL TANK AS REQUIRED IAW MM 79-20-00 AND MM 72-50-00.

Part: SKIN — CORRODED (FS 1783)

DURING PREFLIGHT INSPECTION, FOUND LEVEL 2 CORROSION ON FUSELAGE TAIL SECTION PLATING AT FS 1783, L17L. CUT OUT DAMAGED AREA, FABRICATED, INSTALLED FILLER AND DOUBLER IAW SRM 53-2-1 FIG 7, PG 115 AND 116. CLASS 3 REPAIR TO BE REPLACED BEFORE 6,000 LANDINGS.

Part: SEAL — FAILED (MAIN CARGO DOOR)

AIR TURNBACK, LOUD BANG AND PRESSURE LEAK AT CARGO DOOR AT FL 270. UNABLE TO MAINTAIN PRESSURE WITH FOUR TURBO COMPRESSORS ON AND OUTFLOW VALVE FULL CLOSE. RETURNED TO MIAMI WITHOUT FURTHER INCIDENT. MAINTENANCE FOUND MAIN CARGO DOOR SEAL TORN AND DETERIORATED IN SEVERAL PLACES. REMOVED AND REPLACED CARGO DOOR SEAL. LEAK CHECK GOOD. PRESSURIZATION NORMAL ON GROUND CHECK. (M)

Part: NR 1 ADI — INOP (RADIO RACK)

MIA/SJU - FLT 501 - AFTER DEPARTING MIA EN ROUTE TO SJU, CAPTAIN'S ADI ROLLED OVER. AIRCRAFT RETURNED TO MIA. FOUND NR 1 ADI AND INSTRUMENT RACK AT FAULT. REMOVED AND REPLACED NR 1 ADI AND NR 1 INSTRUMENT AMP RACK. OPS NORMAL IAW 34-23-0. REFERENCE: OPERATOR CONTROL NR 95ZZZX5918. (X)

Part: NR 1 INSTR RACK — INOP (RADIO RACK)

MIA/SJU - FLT 501 - AFTER DEPARTING MIA EN ROUTE TO SJU, CAPTAIN'S ADI ROLLED OVER. AIRCRAFT RETURNED TO MIA. FOUND NR 1 ADI AND INSTRUMENT RACK AT FAULT. REMOVED AND REPLACED NR 1 ADI AND NR 1 INSTRUMENT AMP RACK. OPS NORMAL IAW 34-23-0. REFERENCE: OPERATOR CONTROL NR ARWA0930501.

Part: SKIN — CORRODED (FS 500-520)

DURING PREFLIGHT, FOUND EVIDENCE OF CORROSION BETWEEN FS 500 AND FS 520 BETWEEN L-28R AND L-29R. OPEN UP SKIN, CUT OUT AREA OF CORROSION AND FABRICATE REPAIR DOUBLER AND FINGER DOUBLERS AS PER DWG NR 30942-14. INSTALLED DOUBLERS AND FILLERS AS PER DWG NR ARW 30942-14. (M)

Part: SEAL — LEAKING (MAIN CARGO DOOR)

AIR TURN BACK WITH 4 TC'S ON, CABIN CLIMB AT 1,000 FT/MIN WHEN AIRCRAFT REACHED 20,000 FEET CARGO DOOR SEAL LEAKING, CABIN WENT TO 11,000 FEET. INSTALLED NEW BACKUP SEAL ON ENTIRE MAIN CARGO DOOR AFTER AIRCRAFT WAS LEAK CHECKED AT BLAST FENCE WITH SMOKE CANISTERS. PRESSURIZED AIRCRAFT IAW MM 21-30. NO LEAKS NOTED ON MAIN CARGO DOOR.

Part: ENGINE — FAILED (NR 1)

AFTER 27 MINUTES IN FLIGHT FROM SAN JUAN, PR, WITH DESTINATION MIAMI, FL, THE CREW DESCRIBED THE PROBLEM AS: IN CLIMB-OUT OF 10,000 FEET, GOT LOUD BANG AND ACFT YAW. NR 1 EPR DOWN AND EGT APPROACHING 600 CELSIUS. SHUT ENGINE DOWN AT 17037 AND RETURNED TO SJU. ACFT THREE ENGINE FERRIED TO MIAMI. NR 1 ENGINE REMOVED AND REPLACED.

Part: EEL BATTERY PACK — DISCHARGED (CABIN)

EMERGENCY EXIT LIGHT INOPERATIVE. REMOVED AND REPLACED EMERGENCY BATTERY PACK. SYSTEM OPS CHECK NORMAL IAW DC-8 MM 33-50-00.

Part: LONGERON — CORRODED (FS 1070/1090)

LEVEL 2 CORROSION FOUND ON OUTBOARD FLANGE OF LONGERON 31R BETWEEN FS 1070 AND FS 1090. MECHANICALLY REMOVED CORROSION FROM LONGERON 31R, TREATED AND PRIMED. INSTALLED REPAIR DOUBLER IAW DER DRAWING ARW 30218-10.

Part: LONGERON — CORRODED (FS 1070-1090)

LEVEL II CORROSION FOUND ON OUTBOARD FLANGE OF LONGERON 31R BETWEEN FS 1070 AND FS 1090.

Part: STIFFENER — CORRODED (FS 980)

LEVEL II CORROSION FOUND AFT SIDE FS 980.00 BULKHEAD AT LONGERON 30L ATTACHMENT.

Part: BLKHD STIFFENER — CORRODED (FS 980)

LEVEL 2 CORROSION FOUND AFT SIDE FS 980.00 BULKHEAD AT LONGERON 30L ATTACHMENT. MECHANICALLY REMOVED CORROSION, TREATED, PRIMED AREA, AND INSTALLED REPAIR DOUBLER IAW DER DRAWING ARW 5598-3.

Part: SKIN — CORRODED (FS 1030-1080)

FUSELAGE SKIN BULGED AROUND FASTENERS IN THREE AREAS BETWEEN FS 1030 AND FS 1080 BETWEEN LONGERONS 19L AND 21L. OPENED GILL LINER TO GAIN ACCESS, FOUND LEVEL 3 CORROSION. CUT OUT DAMAGED AREAS AND INSTALLED DOUBLERS AND FILLERS IAW DER DRAWING ARW .29925-12.

Part: SKIN — CORRODED (FS 500 L30R)

FS 500.0, L30R, CORROSION ON SKIN. REPAIRED PER DER ARW 950037-0008 ON FILE.

Part: BULKHEAD — CRACKED (NOSE WHEELWELL)

ACCOMPLISHED REPAIR TO FORWARD PRESS BULKHEAD IN NOSE WHEELWELL. CUT OUT DAMAGED AREA, FABRICATED ALL PARTS PER ARW D85330-3075. INSTALL PARTS IAW ARW D95330-3075.