N495AJ

Part: HYDRAULIC LINE — LOOSE (HYDRAULIC SYS) · airframe 77,658 hrs · 45,010 cycles

HYDRAULIC SYS A FAILURE. DECLARED AN EMER. FOUND NR 1 ENG HYD PUMP PRESS LINE LOOSE IN NR 1 ENG PYLON. THE LINE WAS SECURED, THE HYD SYS SERVICED, ENG OPERATED, FLIGHT CONTROLS CYCLED & LEAK CHECKS PERFORMED IAW THE AMM.

Part: BOLT — MISSING (MLG DOOR) · airframe 77,648 hrs · 45,003 cycles

NOSE LANDING GEAR DOOR LIGHT REMAINED ILLUMINATED AFTER TAKEOFF. REPLACED THE NOSE GEAR SENSOR ACTUATOR ARM BUSHING & BOLT. PERFORMED A LG OPERATIONAL CHECK IAW THE AMM.

Part: FLOORBEAM — CRACKED (BS 1183) · airframe 77,484 hrs · 44,890 cycles

MAIN CARGO COMPARTMENT FLOORBEAM CRACKED 3", BS 1183, RBR 24.5 NEAR WL 263.

Part: SKIN — CRACKED (LT WING) · airframe 77,484 hrs · 44,890 cycles

LT WING UPPER SKIN L/E CRACKED 1.5", WS 410.0.

Part: SKIN — CRACKED (SERVICE DOOR) · airframe 77,484 hrs · 44,890 cycles

ENTRY DOORS, SERVICE DOOR SKIN LOWER PART CRACKED 2".

Part: SKIN — CORRODED (BS 1380.5) · airframe 77,484 hrs · 44,890 cycles

UPPER FUSELAGE SKIN CORRODED AT BS 1380.5.

Part: SKIN — CRACKED (LT WING) · airframe 77,484 hrs · 44,890 cycles

LEFT WING UPPER SKIN L/E CRACKED "WS 546.5 - WS 574.0".

Part: SKIN — CRACKED (LT WING) · airframe 77,484 hrs · 44,890 cycles

LEFT WING UPPER SKIN L/E CRACKED WS 464.0 - 491.5.

Part: SKIN — CRACKED (LT WING) · airframe 77,484 hrs · 44,890 cycles

LEFT WING UPPER SKIN L/E CRACKED .3125" FROM WS 574.0 TO WS 601.5.

Part: SKIN — CRACKED (LT WING) · airframe 77,484 hrs · 44,890 cycles

LEFT WING UPPER SKIN L/E CRACKED FROM WS 410.0 - 436.5.

Part: SPAR — CORRODED (LT WING) · airframe 77,484 hrs · 44,890 cycles

LEFT WING REAR SPAR UPPER FITTING SHOWS CORROSION FROM WS 627.0 TO WS 656.5 WBL 492.5, REF N/R 02747.

Part: SKIN — CRACKED (LT WING) · airframe 77,484 hrs · 44,890 cycles

LEFT WING UPPER SKIN L/E CRACKED .3125" FROM WS 574.0 TO WS 601.5.

Part: FLOW MULTIPLIER — SEIZED (RT MLG WW) · airframe 76,834 hrs · 44,463 cycles

SMOKE & FIRE RT WW. EXTINGUISHER DEPLOYED TO PUT OUT FIRE FROM THE FLOW MULTIPLIER INLET. BURNED COMPONENTS REMOVED. REPLACEMENT IN WORK.

Part: UNKNOWN — VIBRATION (NR 1 ENGINE) · airframe 76,688 hrs · 44,303 cycles

VIBRATION FELT IN NR 1 POWER & FUEL LEVERS. VIBRATION REDUCED WHEN POWER REDUCED, ENG SHUT DOWN. WIND MILLED FOR 45 MINUTES WITH 30-35 PSI OIL PRESS.

Part: FIRE WARNING — FALSE INDICATION (NR 1 NACELLE) · airframe 76,283 hrs · 44,021 cycles

OUT OF FL 180, ENGINE NR 1 FIRE DETECTION LIGHT ILLUMINATED. RAN CHECKLIST, FAULT LIGHT EXTINGUISHED. MX CHECKED THE SYS IAW THE AMM, NO DISCREPANCIES NOTED. A VISUAL INSPECTION OF THE NR 1 FIRE LOOP WAS ACCOMPLISHED, NO DISCREPANCIES WERE FOUND. THE SYS ADJUSTMENT AND TEST IAW THE AMM WAS PERFORMED AND THE FUNCTION WAS NORMAL.

Part: CONTROLLER — FAILED (CABIN PRESSURE) · airframe 76,283 hrs · 44,021 cycles

OUT OF 11,000 FT, PRESSURIZATION IN AUTO MODE FAILED. RAN CHECK LISTS, CALLED COMPANY, STARTED GETTING CONTROL IN MANUAL MODE. MX REPLACED THE PRESSURIZATION CONTROLLER AND THE SYS CHECKED NORMAL IAW THE AMM.

Part: BUSHING — MISSING (OVERHEAT DETECT) · airframe 76,054 hrs · 43,838 cycles

AT FL 250 LOWER CARGO AFT COMPARTMENT FIRE WARNING ILLUMINATED AND REMAINED ON UNTIL SHORT FINAL INTO NAS. MAINTENANCE REMOVED CARGO FROM AFT COMPARTMENT. INSPECTED CARGO AND COMPARTMENT NO EVIDENCE OF FIRE/SMOKE NOTED. ACCOMPLISHED SMOKE DETECTION TEST IAW SECURAPLANE MM SUPPLEMENT. NO FAULTS FOUND. ACCESSED AFT COMPARTMENT PNEUMATIC DUCT SYSTEM AND PERFORMED LEAK CHECK PER AMM. NO LEAKS NOTED. INSPECTED OVERHEAT DETECTION SENSOR. FOUND SEVERAL SENSOR INSULATING BUSHINGS MISSING. INSTALLED MISSING BUSHINGS AND REPLACED ALL AFT LOWER COMPARTMENT SMOKE DETECTORS PER SECURAPLANE MM SUPPLEMENT. THE REMOVED ACCESS PANELS WERE REPLACED AND THE AIRCRAFT RETURNED TO SERVICE.

Part: SHUTOFF VALVE — MALFUNCTIONED (NR 2 ENGINE) · airframe 75,708 hrs · 43,624 cycles

AFTER START, ENGINE NR 2 SHUTDOWN. MAINTENANCE REPLACED THE NR 2 ENGINE FUEL SHUTOFF VALVE PER THE B727 AMM.

Part: FLOORBEAM — CORRODED (FUSELAGE) · airframe 75,408 hrs · 43,444 cycles

DURING ROUTINE C CHECK INSPECTION, MAIN CARGO COMPARTMENT, FLOORBEAM UPPER HORIZONTAL CHORD SHOWS CORROSION AT BS 870 RBL 3 REF N/R 1357.

Part: SKIN — CORRODED (RT HORIZ STAB) · airframe 75,408 hrs · 43,444 cycles

DURING ROUTINE C CHECK INSPECTION, RIGHT HORIZONTAL STABILIZER LOWER SKIN CORRODED AT STAB STA 152 REF N/R 1369.

Part: BEAM — CRACKED (FUSELAGE) · airframe 75,408 hrs · 43,444 cycles

DURING ROUTINE C CHECK INSPECTION, MAIN CARGO COMPT - VERTICAL BEAM FWD FLANGE HAS A 1.5 INCH APPROX CRACK AT BS 1183 LBL 22 WL 222.20 REF N/R 1327.

Part: WINDOW FRAME — CORRODED (CABIN) · airframe 75,408 hrs · 43,444 cycles

DURING ROUTINE C CHECK INSPECTION, MAIN CARGO COMPT - WINDOW FRAME SHOWS CORROSION (BS 720C - 720D, S-1213L) REF N/R 1411.

Part: FITTING — CORRODED (NLG) · airframe 75,408 hrs · 43,444 cycles

DURING ROUTINE C CHECK INSPECTION: NOSE LANDING GEAR - FITTING SHOWS CORROSION AT BS 351 REF N/R 1395.

Part: SKIN — CORRODED (RUDDER) · airframe 75,408 hrs · 43,444 cycles

DURING ROUTINE C CHECK INSPECTION, UPPER RUDDER LEFT SIDE SKIN SHOWS CORROSION STA 230 REF N/R 1397.

Part: SKIN — CRACKED (LE SLAT) · airframe 75,408 hrs · 43,444 cycles

DURING ROUTINE C CHECK INSPECTION, LEFT WING SLAT NR 3 LWR SKIN CRACKED 5/16 INCH APPROX AT SLAT STA 135.0 REF NR 0170.

Part: FRAME — CORRODED (FUSELAGE) · airframe 75,408 hrs · 43,444 cycles

DURING ROUTINE C CHECK INSPECTION, LOWER NOSE COMPT - FRAME WEB CORRODED AT BS 351.2 LBL 9 RBL 18 REF NR 1292.

Part: SPAR — CORRODED (LT WING) · airframe 75,408 hrs · 43,444 cycles

DURING ROUTINE C CHECK INSPECTION, LEFT WING LOWER REAR SPAR CORRODED AT WBL 90 REF NR 0582.

Part: STIFFENER — CORRODED (RT WING) · airframe 75,408 hrs · 43,444 cycles

DURING ROUTINE C CHECK INSPECTION, RIGHT WING FRONT SPAR AREA - STIFFENER CORRODED AT FS 232.0 REF NR 0133.

Part: SPAR — CORRODED (CENTER WING) · airframe 75,408 hrs · 43,444 cycles

DURING ROUTINE C CHECK INSPECTION, WING CENTER SECTION REAR SPAR WEB CORRODED AT STA 870 LBL 30 REF NR 1099.

Part: SKIN — CRACKED (LE SLAT) · airframe 75,408 hrs · 43,444 cycles

DURING ROUTINE C CHECK INSPECTION, RIGHT WING L/E SLAT NR 6 INTERNAL SKIN CRACKED 1 INCH AT SLAT STA 1674.0 REF NR 0379.

Part: FRAME — CRACKED (FUSELAGE) · airframe 75,408 hrs · 43,444 cycles

DURING ROUTINE C CHECK INSPECTION, AIR CONDITIONING DISTRIBUTION BAY - FRAME HAS A 1 INCH CRACK AT BS 740 STRINGER 20 – 21L REF NR 0442.

Part: FRAME — DEFORMED (FUSELAGE) · airframe 75,408 hrs · 43,444 cycles

DURING ROUTINE C CHECK INSPECTION, FWD CARGO COMPT- FRAME DEFORMED BS 580 STR 25L REF NR 0798.

Part: BEAM — CORRODED (LT HORIZ STAB) · airframe 75,408 hrs · 43,444 cycles

DURING ROUTINE C CHECK INSPECTION, LEFT HORIZONTAL TRAILING EDGE BEAM SHOWS CORROSION STAB STA 128 REF NR 0638.

Part: SKIN — NICKED (RT AILERON) · airframe 75,408 hrs · 43,444 cycles

DURING ROUTINE C CHECK INSPECTION, RIGHT WING OUTBOARD AILERON UPPER SURFACE SHOWS NICKS BETWEEN STA WBL 492.5 AND 602.5 REF NR 0127.

Part: SHIM — CORRODED (HORIZ STAB) · airframe 75,408 hrs · 43,444 cycles

DURING ROUTINE C CHECK INSPECTION, RIGHT HORIZONTAL STABILIZER TRAILING EDGE UPPER BEAM SHIM CORRODED STAB STA 62 REF NR 0641.

Part: BEAM — WORN (HORIZ STAB) · airframe 75,408 hrs · 43,444 cycles

DURING ROUTINE C CHECK INSPECTION, LEFT HORIZONTAL STABILIZER TRAILING EDGE UPPER BEAM WORN STAB STA 54 REF NR 0639.

Part: FRAME — DEFORMED (FUSELAGE) · airframe 75,408 hrs · 43,444 cycles

DURING ROUTINE C CHECK INSPECTION, FWD CARGO COMPT FRAME DEFORMED BS 560 STR 25L REF NR 0797.

Part: TORQUE BOX — CORRODED (VERTICAL STAB) · airframe 75,408 hrs · 43,444 cycles

DURING ROUTINE C CHECK INSPECTION, VERTICAL FIN - TORQUE BOX INBOARD CHORD LEFT CORRODED STA 1342 FIN STA 0 AND FWD REAR SPAR CHORD REF NR 0642.

Part: SKIN — CORRODED (HORIZ STAB) · airframe 75,408 hrs · 43,444 cycles

DURING ROUTINE C CHECK INSPECTION, RIGHT HORIZONTAL STABILIZER REAR SPAR AND SKIN LOWER CHORD SHOWS CORROSION STAB STA 152 REF NR 0640.

Part: FRAME — DEFORMED (FUSELAGE) · airframe 75,408 hrs · 43,444 cycles

DURING ROUTINE C CHECK INSPECTION, FWD CARGO COMPT FRAME DEFORMED, BS 540 STR 24L REF NR 0796.

Part: SPAR — CORRODED (HORIZ STAB) · airframe 75,408 hrs · 43,444 cycles

DURING ROUTINE C CHECK INSPECTION, RIGHT HORZ STAB - REAR SPAR AND SKIN LOWER CHORD CORRODED STAB STA 180 REF NR 0637.

Part: ENGINE — FLAMED OUT (NR 3) · airframe 74,067 hrs · 42,310 cycles

CREW LOG ITEM "ENGINE NR 3 SURGED 3 TIMES (EPR N1 & N2). ON THIRD SURGE ENGINE 3 FLAMED OUT (EPR DROP FOLLOWED BY N1 AND EGT). RESTARTED ENGINE AND INDICATIONS NORMAL FOR REMAINDER OF FLIGHT. ENGINE WINDMILLED FOR 10 MINS." MAINTENANCE INSPECTED THE ENGINE INLET, EXHAUST, MAIN OIL FILTER, FUEL FILTER AND FUEL CONTROL SCREEN WITH NO FINDINGS.

Part: CLAMP — LOOSE (HEAT EXCHANGER) · airframe 73,859 hrs · 42,102 cycles

NUMBER 3 ENGINE STRUT OVERHEAT LIGHT ILLUMINATED SHORTLY AFTER TAKEOFF. MAINTENANCE RETORQED THE BLEED AIR HEAT EXCHANGER CLAMP, PERFORMED A LEAK AND OPERATIONAL CHECK ON AN ENGINE RUN-UP.

Part: TUBE — LEAKING (NR 1 ENGINE) · airframe 73,542 hrs · 41,698 cycles

NUMBER 1 ENGINE OIL QUANTITY STEADILY DECREASED DURING FLIGHT. ALSO OIL TEMP EXCESSIVE. ONLY DROPPED DURING POWER BACK. MAINTENANCE FOUND THE NUMBER 6 BEARING OUTER TUBE ON NUMBER 1 ENGINE LEAKING. THE TUBE PART NUMBER 793651 WAS REPLACED AND THE AIRCRAFT RETURNED TO SERVICE.

Part: BATTERY — DISCHARGED (CARGO BAY) · airframe 73,436 hrs · 41,583 cycles

PASSING THROUGH 3000 FT THE LOWER AFT CARGO FIRE ALARM SOUNDED. UPON LANDING MAINTENANCE PERFORMED OPS CHECK OF THE LOWER CARGO COMPT SMOKE DETECTION SYSTEM. FOUND NORMAL PER SECRURAPLANE CMM. NO FREIGHT IN AFT CARGO COMPT. PERFORMED VISUAL INSPECTION OF COMPARTMENT LINER FOR EVIDENCE OF OVERHEAT DAMAGE, NONE FOUND. REMOVED LINER, PERFORMED VISUAL INSPECTION OF DUCTING AND AREAS FOR HEAT AND DUCT DAMAGE, NO DAMAGE NOTED. PERFORMED LEAK CHECK AT T/O POWER. NO LEAKS NOTED. PERFORMED SECOND OPERATIONAL TEST OF THE COMPT SMOKE DETECTOR SYSTEM. FOUND LOW BATTERY AT SDU A4608. REPLACED BATTERY AND SYSTEM OPS CHECK NORMAL. RE-INSTALLED GILL LINER.

Part: FLANGE — CORRODED (ZONE 100) · corrosion level 2 · airframe 73,082 hrs · 41,334 cycles

CORROSION FOUND ON RT MAIN WHEEL WELL OTBD AFT FLANGE AT STA 930 RBL 72 ABOVE MANUAL EXTENSION TORQUE TUBE. REMOVED SUPPORT FITTING FOR ACCESS. REMOVED CORROSION IAW SRM 51-30-2. FABRICATED AND INSTALLED REPAIR DOUBLER IAW EO SIE-AJ-N495AJ-05-09 REV 1R. REPLACED SUPPORT FITTING.

Part: BLADE — BROKEN (NR 1 ENGINE) · airframe 72,512 hrs · 40,893 cycles

AMERIJET FLIGHT SXM - SJU NUMBER ONE ENGINE VIBRATION FOLLOWED BY HIGH FUEL FLOW. PERFORMED A PRECAUTIONARY SHUTDOWN. MAINTENANCE DISCOVERED A BROKEN C2 BLADE AND COMPRESSOR DAMAGE.

Part: TURBINE BLADES — FAILED (NR 3 ENGINE) · airframe 71,633 hrs · 40,218 cycles

FLT 433 MIA-BLA - CREW REPORTED, LOSS POWER ON NUMBER NR 3 ENGINE ON TAKEOFF. THE CAPTAIN REJECTED TAKEOFF ROLL AT APPROXIMATELY 10 KNOTS. AIRCRAFT RETURNED BACK TO AMERIJET LINE MAINTENANCE FACILITY WITHOUT FURTHER INCIDENT. MAINTENANCE FOUND MULTIPLE TURBINE BLADES FAILED AND ENGINE WAS BEYOND LINE MAINTENANCE REPAIR. ENGINE IS SCHEDULED FOR REPLACEMENT AND DAMAGED ENGINE IS BEING SENT TO REPAIR FACILITY. SHOP BORESCOPE INSPECTION REVEALED T-1 VISIBLE BLADES ACCEPTABLE, T-2 BLADES DAMAGED, T-3 AND T-4 BLADES TOTALLY DESTROYED. CONCLUSION - BLADE FAILURES COMMENCED WITH T-3.

Part: OVERHEAT LOOP — OUT OF POSITION (NR 3 STRUT)

AT CRUISE FL 310 AMERIJET FLIGHT 875 NUMBER 3 STRUT OVERHEAT LIGHT ILLUMINATED. LIGHT WENT OUT AFTER 2 MINUTES AND REMAINED OUT WITH ENGINE AT IDLE ONLY. THE FLIGHT DIVERTED TO KIN. MAINTENANCE DISCOVERED THE STRUT OVERHEAT DETECTOR TOUCHING THE PNEUMATIC DUCT. THE ELEMENT WAS REPOSITIONED, A POWER RUN WAS PERFORMED AND THE AIRCRAFT RETURNED TO SERVICE.

Part: WARNING SYSTEM — MULTIPLE FAIL

FLIGHT 611 ON TAKEOFF FROM MIA THE CREW REPORTED THE NR 1 BLEED TRIP LIGHT CAME ON. THE CREW THEN CHANGED TO THE NR 2 BLEED, ONE MINUTE LATER THE NR 1 STRUT OVERHEAT LIGHT CAME ON. THE CREW FOLLOWED THE COMPANY CHECKLIST AND SHUT DOWN THE NR 1 ENGINE; DUMPED FUEL, AND RETURNED TO MIA WITHOUT FURTHER INCIDENT. MAINTENANCE IS IN THE PROCESS OF TROUBLESHOOTING AND EVALUATING THE CAUSE.

Part: BLADES — DAMAGED (NR 1 ENGINE)

ON TAKEOFF CREW REPORTED NR 1 BLEED TRIP LIGHT CAME ON. CHANGED TO NR 2 BLEED, ONE MIN LATER NR 1 STRUT OVERHEAT LIGHT CAME ON. FOLLOWED COMPANY CHECKLIST & SHUT DOWN NR 1 ENGINE; DUMPED FUEL, & RETURNED WITHOUT INCIDENT. INSPECTION OF NR 1 ENGINE FOUND C-1 LOW COMPRESSOR STAGE BLADES 4 EA HAD SUSTAINED FOD DAMAGE, ALSO C-2 LOW COMPRESSOR STAGE BLADES 8 EA SUSTAINED FOD DAMAGE, & C1 STATOR HAD SUSTAINED FOD DAMAGE. ORIGIN OF FOD DAMAGE IS NOT EVIDENT. DAMAGED C-1 & C-2 BLADES, & C1 STATOR WERE REMOVED, REPLACED AND BALANCED. ACCOMPLISHED NR 1 ENGINE RUN PER AMERIJET FORM B-41, OPERATIONAL CHECK GOOD. THE A/C HAS BEEN RETURNED TO SERVICE.

Part: HINGE BRACKET — CORRODED (OVERWING EXIT)

DURING PUSHBACK MAINTENANCE FOUND THE RT AFT OVERWING EXIT STEP MISSING. ON FURTHER INSPECTION MAINTENANCE FOUND CORROSION ON THE RT AFT OVERWING EXIT STEP HINGE HALF, AMERIJET MAINTENANCE INSPECTED THE RIGHT HAND FUSELAGE, THE RIGHT HAND WING AND THE VERTICAL AND HORIZONTAL STABILIZER, AND ENGINE INLET INSPECTION OF THE NR 3 ENGINE WAS ACCOMPLISHED FOR POSSIBLE IMPACT DAMAGE WITH NO DEFECTS NOTED IAW B-727 MM CH 5-51-00. THE RT AFT OVERWING EXIT STEP HINGE HALF WILL BE REPLACED DUE TO CORROSION OF THE HINGE HALF WHICH CAUSED THE STEP TO SEPARATE AT THE HINGE. THE AIRCRAFT WAS RETURNED TO SERVICE.

Part: ACTUATOR — STUCK (ZONE 500) · airframe 67,979 hrs · 38,193 cycles

ON CLIMB, NUMBER 1 SLAT WOULD NOT RETRACT. AIRCRAFT RETURNED TO KMIA AND LANDED WITH NO INCIDENT. MAINTENANCE FOUND NUMBER 1 SLAT ACTUATOR FAILED IN THE EXTENDED POSITION. SLAT ACTUATOR REMOVED AND REPLACED PER B727 MM 27-81-32, OPS AND LEAK CHECK OK. NO DEFECT NOTED.

Part: WHEEL — VIBRATION (NLG)

AT T/O, A SEVERE VIBRATION DURING T/O ROLL. CREW ABORTED T/O AT 100 KNOTS AND COMPLIED WITH AFM PROCEDURES. THE AIRCRAFT RETURNED TO THE BLOCK WITHOUT ANY FURTHER INCIDENT. MAINTENANCE ACCOMPLISHED A CLOSE VISUAL INSPECTION OF THE MAIN TIRES, NO DEFECTS NOTED. ALL EXTERNAL ACCESS DOORS WERE INSPECTED FOR SECURITY, NO DEFECTS NOTED. UPON INSPECTION OF THE NOSE TIRES UNUSUAL TIRE WEAR WAS NOTED. BOTH LEFT AND RIGHT NOSE LANDING GEAR WHEEL AND TIRE ASSEMBLIES WERE REMOVED AND REPLACED IAW B-727 MM CH 32-45-11. A HIGH ENERGY STOP CONDITION INSPECTION WAS ACCOMPLISHED IAW B-727 MM CH 5-51-76 DUE TO THE ABORTED TAKEOFF, NO DEFECTS WERE NOTED. THE AIRCRAFT WAS RETURNED TO SERVICE.

Part: THERMAL SWITCH — INTERMITTENT (BLEED AIR SYS)

CREW PREPARED FOR TAKEOFF, CREW REPORTED NR 1 ENGINE BLEED TRIPPED WHEN TAKEOFF POWER SET. AIRCRAFT RETURNED TO BLOCK WITHOUT INCIDENT. MX TROUBLESHOT & ACCOMPLISHED OPERATIONAL CHECKS OF THE BLEED SYSTEM AND COULD NOT DUPLICATE THE PROBLEM, THE AMERIJET FLIGHT CREW ACCOMPANIED MAINTENANCE AND A HIGH SPEED TAXI WAS ACCOMPLISHED AND WERE ABLE TO DUPLICATE THE PROBLEM. MAINTENANCE REPLACED THE NUMBER 1 ENGINE THERMAL SWITCH & LEFT SIDE HIGH PRESSURE REGULATOR. LEAK CHECK & OPS CHECKOUT GOOD. AMERIJET FLIGHT CREW ACCOMPANIED THE MAINTENANCE MECHANICS ON THE OPERATIONAL CHECKS AND ACCOMPLISHED ANOTHER HIGH SPEED TAXI CHECK, HIGH SPEED TAXI CHECKOUT WAS GOOD. THE AIRCRAFT WAS RETURNED TO SERVICE.

Part: FLAP — MALFUNCTIONED (WING)

FLIGHT 839 DEPARTED MIA AND DURING THE CLIMB THE CREW REPORTED THE INBOARD FLAPS WERE STUCK AT 5 DEGREES, THE AIRCRAFT RETURNED BACK AND LANDED AT MIA WITH NO FURTHER INCIDENT. MAINTENANCE PERFORMED A GENERAL VISUAL INSPECTION OF THE INBOARD FLAP SYSTEM IAW B-727 MM CH 27-52-02, COULD NOT DUPLICATE THE PROBLEM ON THE GROUND. MAINTENANCE PERFORMED AN OPERATIONAL CHECK ON THE FLAP SYSTEM IAW B-727 MM CH 27-52-02, FOUND NORMAL. AIRCRAFT WAS RETURNED TO SERVICE.

Part: MODULATING VALVE — MALFUNCTIONED (NR 1 ENGINE)

FLIGHT 839 DURING PREPARATION FOR TAKEOFF, THE CREW REPORTED THE NUMBER 1 ENGINE BLEED TRIPPED WHEN TAKEOFF POWER WAS SET, 95 PSI DUCT PRESSURE INDICATED. THE AIRCRAFT RETURNED TO THE BLOCK WITHOUT ANY FURTHER INCIDENT. MAINTENANCE TROUBLESHOT AND REPLACED THE NUMBER 1 ENGINE HIGH PRESSURE MODULATING AND SHUTOFF VALVE IAW MM-36-12-42, ACCOMPLISHED ENGINE RUN PER AMJ FORM M-53 AT TAKEOFF POWER FOR 3 MINUTES, THE DUCT PRESSURE READ 65 PSI MAX. OPERATIONAL CHECK AND LEAK CHECK OK, IAW MM 36-12-02. THE AIRCRAFT WAS RETURNED TO SERVICE.

Part: OUTFLOW VALVE — STUCK (RT A/C PACK)

FLIGHT 731 AFTER DEPARTURE, DURING CLIMB THRU 6000 FT. CREW REPORTED CABIN PRESSURIZATION STARTED CLIMBING AT AN EXCESSIVE RATE AND COULD NOT MAINTAIN CABIN PRESSURIZATION. THE CREW REPORTED THE OUTFLOW VALVE WAS FULLY CLOSED, IT APPEARED THAT THE RT PACK WAS CLOSED. THE CREW DUMPED FUEL AND RETURNED TO DEPARTURE WITHOUT ANY FURTHER INCIDENT. MAINTENANCE FOUND THE RT PACK VALVE CLOSED AND NOT OPENING, THE RT PACK VALVE WAS REMOVED AND REPLACED IAW MM CH 21-55-71, THE SYSTEM WAS OPERATIONALLY CHECKED AND FOUND NORMAL AND A DECAY CHECK WAS FOUND NORMAL IAW MM CH 5-51-101.

Part: FLAP SYSTEM — DISCONNECTED (TE FLAPS)

ON CLIMBOUT, CREW REPORTED OB TRAILING EDGE FLAPS WOULD NOT RETRACT AFTER TAKEOFF. AIRCRAFT RETURNED TO DEPARTURE AND LANDED WITHOUT FURTHER INCIDENT. MAINTENANCE TROUBLESHOT OB FLAP POSITIONING SYSTEM, THE OB FLAP POSITION INDICATOR CONNECTOR WAS SUSPECTED NOT MAKING PROPER CONTACT, PIN CONNECTOR WAS DISCONNECTED AND CLEANED AND RECONNECTED, SYSTEM WAS OPERATIONALLY CHECKED TO BE OPERATING NORMAL IAW MM CH 27-52-21. AIRCRAFT WAS RETURNED TO SERVICE.

Part: WINDSHIELD — CRACKED (COCKPIT)

FLIGHT 8213 DURING CLIMBOUT FROM MIA CREW REPORTED LEFT HAND L1 CAPTAINS WINDSHIELD CRACKED. AIRCRAFT RETURNED BACK TO MIA AND LANDED WITH NO FURTHER INCIDENT. MAINTENANCE REMOVED AND REPLACED CAPTAINS L1 WINDSHIELD IAW B727 MM CH 56-11-11 AND REMOVED AND REPLACED THE WINDOW HEAT CONTROLLER IAW B727 MM CH 30-41-02, OPERATIONALY CHECKED NORMAL IAW B727 MM CH 30-41-02. AIRCRAFT WAS RETURNED TO SERVICE.

Part: CONNECTOR — DIRTY (FLAP INDICATOR) · airframe 67,023 hrs · 37,658 cycles

FLIGHT 8113 TTPP/SVMC - AFTER DEPARTURE FROM TTPP, CREW REPORTED UNABLE TO RETRACT OUTBOARD FLAPS FROM 5 DEGREES. RETURNED AIRCRAFT TO TTPP USING THE SPLIT FLAP ALTERNATE PROCEDURE IAW AMERIJET 727 AIRCRAFT OPS MANUAL CHAPTER 5 PAGE 53 AND 54. AIRCRAFT LANDED WITHOUT FURTHER INCIDENT. MAINTENANCE REMOVED INDICATOR CONNECTOR , CLEANED AND RESEATED. PERFORMED OPERATIONAL CHECK NORMAL IAW MM CHAPTER 27-51-00. AIRCRAFT RETURNED TO SERVICE.

Part: CONNECTOR — LOOSE (L/E SLAT)

FLIGHT 846 DURING CLIMB FROM KIN CREW REPORTED LEADING EDGE AMBER LIGHT CAME ON, CYCLED FLAPS TO 5 DEGREES AND BACK TO 0 DEGREES. LIGHT REMAINED ON, CONFIRMED WITH FLT ENGINEER FLAP SLAT ANNUNCIATOR PANEL. FOLLOWED INOPERATIVE L/E FLAP/SLATS ALTERNATE PROCEDURE. CREW DIVERTED TO SDQ LANDED WITH NO FURTHER INCIDENT. CREW REPORTED AFTER LANDING FLAPS WERE RETRACTED, AMBER LIGHT WENT OUT. MAINTENANCE INSPECTED L/E FLAP/SLAT SYSTEM IN SDQ, FOUND NR 4 L/E SLAT PROXIMITY SWITCH CONNECTOR LOOSE. SECURED TWO LOOSE NUTS, & CLEANED ELECTRICAL CONNECTOR, IAW B-727 MM CH 27-82-11. ACCOMPLISHED 3 RECYCLES FOR L/E FLAP/SLATS IAW B-727 MM CH 27-82-0, OPERATIONAL CHECKED OK. A/C WAS RETURNED TO SERVICE.

Part: CDU — SHORTED (AFT CARGO)

FLIGHT 711 MIA TO MEX, DURING CRUISE LOWER CARGO FIRE LIGHT AND BELL CAME ON INDICATING A AFT FIRE. FUEL WAS DUMPED, AIRCRAFT DIVERTED TO MID AND LANDED WITH NO FURTHER INCIDENT. UPON INSPECTION OF THE AFT CARGO COMPARTMENT ON THE GROUND NO FIRE WAS OBSERVED IN THE AFT CARGO. MAINTENANCE FOUND A CDU IN THE AFT CARGO SENDING FALSE FIRE INDICATION TO COCKPIT, CDU EXTERNAL WIRE FOUND GROUNDING, WIRE REPAIRED IAW 20-10-13, SYSTEM OP'S CHECK NORMAL IAW HOLLYNDSED AMMS 26-15-00. AIRCRAFT WAS RETURNED TO SERVICE.

Part: INDICATOR — INOPERATIVE (TE FLAPS)

ON TAKEOFF FROM KMIA, OUTBOARD FLAP STAYED AT 20 DEGREES CREATING SPLIT FLAP CONDITION. AIRCRAFT DIVERTED BACK TO KMIA AND LANDED WITHOUT FURTHER INCIDENT. MAINTENANCE REMOVED AND REPLACED OUTBOARD TRAIILNG EDGE FLAP INDICATOR IAW MM 27-56-10. AIRCRAFT RETURNED TO SERVICE. (M)

Part: VALVE — FAILED (NR 3 ENGINE)

FLT 811 - KMIA-TBPB, DURING LEVEL CRUISE, NR 3 ENGINE BEGAN TO SURGE AND ALL ENGINE INDICATORS FLUCTUATED. NR 3 ENGINE WAS SHUTDOWN FOR PRECAUTIONS. AIRCRAFT DIVERTED BACK TO KMIA AND LANDED WITHOUT FURTHER INCIDENT. MAINTEANCNE REMOVED AND REPLACED NR 3 ENGINE PRBC VALVE IAW B727 MM 75-31-11. OPS CHECKED GOOD IAW PWA MM 73-00. PERFORMED ENGINE RUN PER AMJ FORM B-41 AND PWA MM 71-00, OPS CHECK GOOD. AIRCRAFT RETURNED TO SERVICE. (M)

Part: INDICATOR — DEFECTIVE (TE FLAPS)

FLT 855 - KMIA-MTPP - AFTER TAKEOFF, PILOT REPORTED ASYMMETRIC OUTBOARD FLAP LOCKS OUT. AIRCRAFT DIVERTED BACK TO KMIA AND LANDED WITHOUT FURTHER INCIDENT. MAINTENANCE FOUND OUTBOARD FLAP POSITION INDICATOR DEFECTIVE. REMOVED AND REPLACED OUTBOARD FLAP POSITION INDICATOR IAW MM 27-51-0, OPS CHECK OK. INSPECTED FLAPS POSITION TRANSMITTER CABLES AND PULLEYS, LUBRICATED CABLES AND PULLEYS, IAW MM 27-51-0. AIRCRAFT RETURNED BACK TO SERVICE. (M)

Part: VALVE — LEAKING (NR 3 ENGINE)

DURING CLIMB-OUT, F/E REPORTED NR 3 ENG FIRE WARNING LIGHT ILLUMINATED. CAPTAIN FOLLOWED EMERGENCY PROCEDURES. A/C DIVERTED TO KMIA & LANDED WITHOUT FURTHER INCIDENT. MX OPENED COWLING & FOUND EVIDENCE OF FLASH FIRE. FOUND STARTER WITH INTERNAL FAILURE, INSPECTED P/D VALVE & FOUND A LOOSE B-NUT WITH EVIDENCE OF FUEL LEAK, CLEANED GEN FEEDER WIRES NO DEFECT NOTED, INSPECTED INLET & TURBINE SECTION, NO DAMAGE FOUND. R & R STARTER, P/D VALVE, START VALVE, CSD INLINE SCREEN FILTER MOUNTING BOLTS & GEN FEEDER WIRE PER MM, & SWPM 20-10-11. REMOVED MAIN OIL FILTER & FOUND NO DEFECTS. R & R DISCHARGED LT FIRE BOTTLE IAW MM 26. RAN ALL ENGS IAW P/W MM 72-00, NO DEFECT NOTED. A/C RETURNED BACK TO SERVICE. (M)

Part: TURBINE BLADE — FAILED (NR 3 ENGINE)

DURING TAKEOFF FROM MIAMI, THE NR 3 ENGINE COMPRESSOR STALLED, THE ENGINE FAIL LIGHT ILLUMINATED. EPR WS 2.13, EGT WAS 595 DEGREES. THE CREW REDUCED POWER ON THE NR 3 ENGINE AND RETURNED TO MIAMI FOR AN UNEVENTFUL LANDING. AIRCRAFT WAS TWO ENGINE FERRIED FROM MIA TO FLL FOR MAINTENANCE. BOROSCOPE INSPECTION REVEALED TWO T-1 BLADE TIPS BROKEN OFF. THE NR 3 ENGINE WAS REMOVED AND REPLACED WITH A SPARE ENGINE FROM STOCK. (M)

Part: ENGINE — MALFUNCTIONED (NR 3)

DURING TAKEOFF FROM MIAMI, THE NR 3 ENGINE EGT WENT TO 595 DEGREES. THE CREW REDUCED POWER ON THE NR 3 ENGINE AND RETURNED TO MIAMI FOR AN UNEVENTFUL LANDING. MAINTENANCE IS TROUBLESHOOTING.

Part: FUEL FILTER — DIRTY (NR 1 ENGINE)

DURING CLIMB-OUT FROM MIAMI, NR 1 ENGINE INDICATIONS FLUCTUATED, CREW REDUCED POWER TO IDLE AND RETURNED TO MIAMI FOR AN UNSCHEDULED LANDING. MAINTENANCE DRAINED FCU MOISTURE TRAP, CLEANED FCU FUEL FILTER AND P AND D VALVE FILTER. ACCOMPLISHED TEST FLIGHT WITH NO FLUCTUATING INDICATIONS NOTED. RETURNED TO SERVICE.